Abrasive article and method of forming

ABSTRACT

An abrasive article including a substrate as an elongated member, a first layer overlying the substrate, abrasive particles overlying the first layer, fillets connecting the first layer and the abrasive particles, a bonding layer overlying the abrasive particles, the first layer and the fillets, and the fillets have a fillet characteristic relative to an abrasive application, the fillet characteristic selected from the group consisting of tacking factor (t fl /t f ), a fillet-to-particle factor (t f /d ab ), a fillet-to-bonding layer factor (t f /t bl ), a contact factor (A b /A f ), a fillet size variance (V f ), and a combination thereof.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. §119(e) to U.S. PatentApplication No. 61/813,815, entitled “Abrasive Article and Method ofForming”, by Rehrig et al., filed Apr. 19, 2013, which is assigned tothe current assignee hereof and incorporated herein by reference in itsentirety. This application further claims priority under 35 U.S.C.§119(e) to U.S. Patent Application No. 61/813,833, entitled “AbrasiveArticle and Method of Forming,” by Tian et al., filed Apr. 19, 2013,which is assigned to the current assignee hereof and incorporated hereinby reference in its entirety.

FIELD OF THE DISCLOSURE

The following is directed to methods of forming abrasive articles, andparticularly, single-layered abrasive articles.

DESCRIPTION OF THE RELATED ART

A variety of abrasive tools have been developed over the past centuryfor various industries for the general function of removing materialfrom a workpiece, including for example, sawing, drilling, polishing,cleaning, carving, and grinding. In particular reference to theelectronics industry, abrasive tools suitable for slicing crystal ingotsof material to form wafers is particularly pertinent. As the industrycontinues to mature, ingots have increasingly larger diameters, and ithas become acceptable to use loose abrasives and wire saws for suchworks due to yield, productivity, affected layers, dimensionalconstraints and other factors.

Generally, wire saws are abrasive tools that include abrasive particlesattached to a long length of wire that can be spooled at high speeds toproduce a cutting action. While circular saws are limited to a cuttingdepth of less than the radius of the blade, wire saws can have greaterflexibility allowing for cutting of straight or profiled cutting paths.

Various approaches have been taken in conventional fixed abrasive wiresaws, such as producing these articles by sliding steel beads over ametal wire or cable, wherein the beads are separated by spacers. Thesebeads may be covered by abrasive particles which are commonly attachedby either electroplating or sintering. However, electroplating andsintering operations can be time consuming and thus costly ventures,prohibiting rapid production of the wire saw abrasive tool. Most ofthese wire saws have been used in applications, where kerf loss is notso dominating as in electronics applications, often to cut stone ormarble. Some attempts have been made to attach abrasive particles viachemical bonding processes, such as brazing, but such fabricationmethods reduce the tensile strength of the wire saw, and the wire sawbecomes susceptible to breaking and premature failure during cuttingapplications under high tension. Other wire saws may use a resin to bindthe abrasives to the wire. Unfortunately, the resin bonded wire sawstend to wear quickly and the abrasives are lost well before the usefullife of the particles is realized, especially when cutting through hardmaterials.

Accordingly, the industry continues to need improved abrasive tools,particularly in the realm of wire sawing.

SUMMARY

According to a first aspect, an abrasive article may include a substratecomprising an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer; fillets connecting thefirst layer and the abrasive particles and a bonding layer overlying theabrasive particles, the first layer and the fillets. The fillets mayhave a fillet characteristic relative to an abrasive application. Thefillet characteristic may be selected from the group consisting of atacking factor (t_(fl)/t_(f)), a fillet-to-particle factor(t_(f)/d_(ab)), a fillet-to-bonding layer factor (t_(f)/t_(bl)), acontact factor (A_(b)/A_(f)), a fillet size variance (V_(f)), and acombination thereof.

For another aspect, an abrasive article may include a substratecomprising an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer, fillets connecting thefirst layer and the abrasive particles and a bonding layer overlying theabrasive particles, the first layer and the fillets. The fillets mayhave a fillet characteristic adapted to an abrasive application. Thefillet characteristic may be selected from the group consisting of atacking factor (t_(fl)/t_(f)), a fillet-to-particle factor(t_(f)/d_(ab)), a fillet-to-bonding layer factor (t_(f)/t_(bl)), acontact factor (A_(b)/A_(f)), a fillet size variance (V_(f)), and acombination thereof.

In yet another aspect, an abrasive article may include a substratecomprising an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer, fillets connecting thefirst layer and the abrasive particles, and a fillet characteristiccomprising a fillet-to-particle factor (t_(f)/d_(ab)) for an abrasiveapplication of the abrasive article, wherein t_(f) represents an averagemaximum thickness of the fillets and d_(ab) represents a median particlesize of the abrasive particles.

According to another aspect, an abrasive article may include a substratecomprising an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer, fillets connecting thefirst layer and the abrasive particles and a fillet characteristiccomprising a tacking factor (t_(fl)/t_(f)) for an abrasive applicationof the abrasive article, wherein t_(fl) represents an average thicknessof the first layer and t_(f) represents an average maximum thickness ofthe fillets.

For yet another aspect, a method of forming an abrasive article mayinclude providing a body including abrasive particles overlying a firstlayer, the first layer overlying a substrate, processing at least thesubstrate, the first layer, and the abrasive particles according to acontrolled processing condition to form an abrasive article having afillet characteristic relative to an abrasive application, the filletcharacteristic selected from the group consisting of a tacking factor(t_(fl)/t_(f)), a fillet-to-particle factor (t_(f)/d_(ab)), afillet-to-bonding layer factor (t_(f)/t_(bl)), a contact factor(A_(b)/A_(f)), a fillet size variance (V_(f)), and a combinationthereof. The controlled processing condition may be selected from thegroup consisting of re-flow temperature, filler content, filler size,filler composition, average particle size of the abrasive particles,size distribution of the abrasive particles, content of the abrasiveparticles, composition of the abrasive particles, thickness of the firstlayer, composition of the first layer, atmospheric conditions, and acombination thereof.

According to another aspect, an abrasive article may comprise asubstrate that may comprise an elongated member, a first layer overlyingthe substrate, abrasive particles overlying the first layer, filletsconnecting the first layer and the abrasive particles and a tackingfactor (t_(fl)/t_(f)) of not greater than about 1.5, wherein t_(fl)represents an average thickness of the first layer and t_(f) representsan average thickness of the fillets.

For another aspect, an abrasive article may comprise a substrate thatmay comprise an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer, fillets connecting thefirst layer and the abrasive particles and a fillet-to-particle factor(t_(f)/d_(ab)) of not greater than about 0.33, wherein t_(f) representsan average thickness of the fillets and d_(ab) represents an averageparticle size of the abrasive particles.

In yet another aspect, an abrasive article may comprise a substrate thatmay comprise an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer, fillets connecting thefirst layer and the abrasive particles and a bonding layer overlying theabrasive particles, the first layer and the fillets. A majority of theabrasive particles may have an undercut region defining a portion of thebonding layer extending under a portion of the abrasive particle betweenthe abrasive particle and the tacking layer.

According to another aspect, an abrasive article may comprise asubstrate that may comprise an elongated member, a first layer overlyingthe substrate, abrasive particles overlying the first layer, filletsconnecting the first layer and the abrasive particles and a bondinglayer overlying the abrasive particles, the first layer an the fillets.The abrasive particles may have a contact factor (A_(b)/A_(f)) of atleast about 1, wherein A_(b) represents an average percentage of asurface area of the abrasive particles in contact with the bonding layerand A_(f) represents an average percentage of the surface area of theabrasive particles in content with the fillets.

In yet another aspect, an abrasive article may comprise a substrate thatmay comprise an elongated member, a first layer overlying the substrate,abrasive particles overlying the first layer, fillets connecting thefirst layer and the abrasive particles, a bonding layer overlying theabrasive particles, the first layer and the fillets, at least one filletcharacteristic selected from the group consisting of a tacking factor(t_(fl)/t_(f)) of not greater than about 1.5, a fillet-to-particlefactor (t_(f)/d_(ab)) of not greater than about 0.33, afillet-to-bonding layer factor (t_(f)/t_(bl)) of not greater than about100, a contact factor (A_(b)/A_(f)) of at least about 1, a fillet sizevariance (V_(f)) of not greater than 60% or a combination thereof. Thefirst layer may further comprise an average thickness of at least about6% of an average particle size of the abrasive particles.

In still another aspect, a method of forming an abrasive article maycomprise providing a body including abrasive particles overlying a firstlayer, the first layer overlying a substrate, processing at least thesubstrate, the first layer, and the abrasive particles according to acontrolled processing condition to form an abrasive article having afillet characteristic selected from the group consisting of a tackingfactor (t_(fl)/t_(f)) of not greater than about 1.5, afillet-to-particle factor (t_(f)/d_(ab)) of not greater than about 0.33,a fillet-to-bonding layer factor (t_(f)/t_(bl)) of not greater thanabout 100, a contact factor (A_(b)/A_(f)) of at least about 1, a filletsize variance (V_(f)) of not greater than 60% or a combination thereof.The controlled processing condition may be selected from the groupconsisting of re-flow temperature, filler content, filler size, fillercomposition, average particle size of the abrasive particles, sizedistribution of the abrasive particles, content of the abrasiveparticles, composition of the abrasive particles, thickness of the firstlayer, composition of the first layer, and a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1 includes a flow chart providing a process for forming an abrasivearticle in accordance with an embodiment.

FIG. 2A includes a cross-sectional illustration of a portion of anabrasive article in accordance with an embodiment.

FIG. 2B includes a cross-sectional illustration of a portion of anabrasive article including a barrier layer in accordance with anembodiment.

FIG. 2C includes a cross-sectional illustration of a portion of anabrasive article including an optional coating layer in accordance withan embodiment.

FIG. 2D includes a cross-sectional illustration of a portion of anabrasive article including a first type of abrasive particle and asecond type of abrasive particle in accordance with an embodiment.

FIG. 3 includes a magnified image of an abrasive article formedaccording to an embodiment.

FIG. 4 includes a magnified image of an abrasive article formedaccording to another embodiment.

FIG. 5 includes a magnified image of an abrasive article formedaccording to another embodiment.

FIG. 6 includes a magnified image of an abrasive article formedaccording to yet another embodiment.

FIG. 7 includes a magnified image of an abrasive article formedaccording to still another embodiment.

FIG. 8 includes a magnified image of an abrasive article formedaccording to another embodiment.

FIG. 9 includes an illustration of an exemplary agglomerated particleaccording to an embodiment.

FIG. 10A includes an illustration of a portion of an abrasive articleaccording to an embodiment.

FIG. 10B includes a cross-sectional illustration of a portion of theabrasive article of FIG. 10A according to an embodiment.

FIG. 10C includes an illustration of a portion of an abrasive articleaccording to an embodiment.

FIG. 11A includes an illustration of a portion of an abrasive articleincluding a lubricious material according to an embodiment.

FIG. 11B includes an illustration of a portion of an abrasive articleincluding a lubricious material according to an embodiment.

FIG. 12A includes an illustration of a portion of an abrasive articleincluding an abrasive particle having an exposed surface according to anembodiment.

FIG. 12B includes a picture of a portion of an abrasive articleincluding abrasive particles having exposed surfaces according to anembodiment.

FIG. 13 includes a cross-sectional picture of an abrasive articleincluding abrasive agglomerates according to an embodiment.

FIG. 14 includes a chart of relative wafer break strength for wafersprocessed by a conventional sample and wafers processed by an abrasivearticle representative of an embodiment.

FIG. 15 includes an illustration of a reel-to-reel machine using anabrasive article to slice a workpiece.

FIG. 16 includes an illustration of an oscillation machine using anabrasive article to slice a workpiece.

FIG. 17 includes an exemplary plot of wire speed versus time for asingle cycle of a variable rate cycle operation.

FIG. 18a includes an illustration of a portion of an abrasive articleincluding fillets according to an embodiment.

FIG. 18b includes an illustration of a magnified portion of FIG. 18 a.

FIG. 19a includes illustrations of an abrasive article including anundercut region according to an embodiment.

FIG. 19b includes an illustration of a magnified portion of FIG. 19 a.

FIG. 20a includes illustrations of an abrasive article including anundercut region according to an embodiment.

FIG. 20b includes an illustration of a magnified portion of FIG. 20 a.

FIG. 21 includes a magnified image of an abrasive article according toan embodiment.

FIG. 22 includes a magnified image of an abrasive article according toan embodiment.

DETAILED DESCRIPTION

The following is directed to abrasive articles, and particularlyabrasive articles suitable for abrading and sawing through workpieces.In particular instances, the abrasive articles herein can form wiresaws, which may be used in processing of sensitive, crystallinematerials in the electronics industry, optics industry, and otherassociated industries.

FIG. 1 includes a flow chart providing a process of forming an abrasivearticle in accordance with an embodiment. The process can be initiatedat step 101 by providing a substrate. The substrate can provide asurface for affixing abrasive materials thereto, thus facilitating theabrasive capabilities of the abrasive article.

In accordance with an embodiment, the process of providing a substratecan include a process of providing a substrate having an elongated body.In particular instances, the elongated body can have an aspect ratio oflength:width of at least 10:1. In other embodiments, the elongated bodycan have an aspect ratio of at least about 100:1, such as at least1000:1, or even at least about 10,000:1. The length of the substrate canbe the longest dimension measured along a longitudinal axis of thesubstrate. The width can be a second longest (or in some cases smallest)dimension of the substrate measured perpendicular to the longitudinalaxis.

Furthermore, the substrate can be in the form of elongated body having alength of at least about 50 meters. In fact, other substrates can belonger, having an average length of at least about 100 meters, such asat least about 500 meters, at least about 1,000 meters, or even 10,000meters.

Furthermore, the substrate can have a width that may not be greater thanabout 1 cm. In fact, the elongated body can have an average width of notgreater than about 0.5 cm, such as not greater than about 1 mm, notgreater than about 0.8 mm, or even not greater than about 0.5 mm. Still,the substrate may have an average width of at least about 0.01 mm, suchas at least about 0.03 mm. It will be appreciated that the substrate canhave an average width within a range between any of the minimum andmaximum values noted above.

In certain embodiments, the elongated body can be a wire having aplurality of filaments braided together. That is, the substrate can beformed of many smaller wires wound around each other, braided together,or fixed to another object, such as a central core wire. Certain designsmay utilize plano wire as a suitable structure for the substrate. Forexample, the substrate can be a high strength steel wire having a breakstrength of at least about 3 GPa. The substrate break strength can bemeasured by ASTM E-8 for tension testing of metallic materials withcapstan grips. The wire may be coated with a layer of a particularmaterial, such as a metal, including for example, brass.

The elongated body can have a certain shape. For example, the elongatedbody can have a generally cylindrical shape such that it has a circularcross-sectional contour. In using elongated bodies having a circularcross-sectional shape, as viewed in a plane extending transversely tothe longitudinal axis of the elongated body.

The elongated body can be made of various materials, including forexample, inorganic materials, organic materials (e.g., polymers andnaturally occurring organic materials), and a combination thereof.Suitable inorganic materials can include ceramics, glasses, metals,metal alloys, cements, and a combination thereof. In certain instances,the elongated body can be made of a metal or metal alloy material. Forexample, the elongated body may be made of a transition metal ortransition metal alloy material and may incorporate elements of iron,nickel, cobalt, copper, chromium, molybdenum, vanadium, tantalum,tungsten, and a combination thereof.

Suitable organic materials can include polymers, which can includethermoplastics, thermosets, elastomers, and a combination thereof.Particularly useful polymers can include polyimides, polyamides, resins,polyurethanes, polyesters, and the like. It will further be appreciatedthat the elongated body can include natural organic materials, forexample, rubber.

To facilitate processing and formation of the abrasive article, thesubstrate may be connected to a spooling mechanism. For example, thewire can be fed between a feed spool and a receiving spool. Thetranslation of the wire between the feed spool and the receiving spoolcan facilitate processing, such that for example, the wire may betranslated through desired forming processes to form the componentlayers of the finally-formed abrasive article while being translatedfrom the feed spool to the receiving spool.

In further reference to the process of providing a substrate, it will beappreciated that the substrate can be spooled from a feed spool to areceiving spool at a particular rate to facilitate processing. Forexample, the substrate can be spooled at a rate of not less than about 5m/min from the feed spool to the receiving spool. In other embodiments,the rate of spooling can be greater, such that it is at least about 8m/min, at least about 10 m/min, at least about 12 m/min, or even atleast about 14 m/min. In particular instances, the spooling rate may benot greater than about 500 m/min, such as not greater than about 200m/min. The rate of spooling can be within a range between any of theminimum and maximum values noted above. It will be appreciated thespooling rate can represent the rate at which the finally-formedabrasive article can be formed.

After providing a substrate at step 101, the process can continue at anoptional step 102 that includes providing a barrier layer overlying thesubstrate. According to one aspect, the barrier layer can be overlying aperipheral surface of a substrate, such that it may be in direct contactwith the peripheral surface of the substrate, and more particularly, canbe bonded directly to the peripheral surface of the substrate. In oneembodiment, the barrier layer can be bonded to the peripheral surface ofthe substrate and may define a diffusion bond region between the barrierlayer and the substrate, characterized by an interdiffusion of at leastone metal element of the substrate and one element of the barrier layer.In one particular embodiment, the barrier layer can be disposed betweenthe substrate and other overlying layers, including for example, a firstlayer, a bonding layer, a coating layer, a layer of a first type ofabrasive particles, a layer of a second type of abrasive particles, anda combination thereof.

The process of providing a substrate having a barrier layer can includesourcing such a construction or fabricating such a substrate and barrierlayer construction. The barrier layer can be formed through varioustechniques, including for example, a deposition process. Some suitabledeposition processes can include, printing, spraying, dip coating, diecoating, plating (e.g., electrolyte or electroless), and a combinationthereof. In accordance with an embodiment, the process of forming thebarrier layer can include a low temperature process. For example, theprocess of forming the barrier layer can be conducted at a temperatureof not greater than about 400° C., such as, not greater than about 375°C., not greater than about 350° C., not greater than about 300° C., oreven not greater than about 250° C. Furthermore, after forming thebarrier layer it will be appreciated that further processing can beundertaken including for example cleaning, drying, curing, solidifying,heat treating, and a combination thereof. The barrier layer can serve asa barrier to chemical impregnation of the core material by variouschemical species (e.g., hydrogen) in subsequent plating processes.Moreover, the barrier layer may facilitate improved mechanicaldurability.

In one embodiment, the barrier layer can be a single layer of material.The barrier layer can be in the form of a continuous coating, overlyingthe entire peripheral surface of the substrate. The barrier material caninclude an inorganic material, such as a metal or metal alloy material.Some suitable materials for use in the barrier layer can includetransition metal elements, including but not limited to tin, silver,copper, nickel, titanium, and a combination thereof. In one embodiment,the barrier layer can be a single layer of material consistingessentially of tin. In one particular instance, the barrier layer cancontain a continuous layer of tin having a purity of at least 99.99%tin. Notably, the barrier layer can be a substantially pure, non-alloyedmaterial. That is, the barrier layer can be a metal material (e.g., tin)made of a single metal material.

In other embodiments, the barrier layer can be a metal alloy. Forexample, the barrier layer can include a tin alloy, such as acomposition including a combination of tin and another metal, includingtransition metal species such as copper, silver, and the like. Somesuitable tin-based alloys can include tin-based alloys including silver,and particularly Sn96.5/Ag3.5, Sn96/Ag4, and Sn95/Ag5 alloys. Othersuitable tin-based alloys can include copper, and particularly includingSn99.3/Cu0.7 and Sn97/Cu3 alloys. Additionally, certain tin-based alloyscan include a percentage of copper and silver, including for example,Sn99/Cu0.7/Ag0.3, Sn97/Cu2.75/Ag0.25 and, Sn95.5/Ag4/Cu0.5 alloys.

In another aspect, the barrier layer can be formed from a plurality ofdiscrete layers, including for example, at least two discrete layers.For example, the barrier layer can include an inner layer and an outerlayer overlying the inner layer. According to an embodiment, the innerlayer and outer layer can be directly contacting each other, such thatthe outer layer is directly overlying the inner layer and joined at aninterface. Accordingly, the inner layer and outer layer can be joined atan interface extending along the length of the substrate.

In one embodiment, the inner layer can include any of thecharacteristics of the barrier layer described above. For example, theinner layer can include a continuous layer of material including tin,and more particularly, may consist essentially of tin. Moreover, theinner layer and outer layer can be formed of different materialsrelative to each other. That is, for example, at least one elementpresent within one of the layers can be absent within the other layer.In one particular embodiment, the outer layer can include an elementthat is not present within the inner layer.

The outer layer can include any of the characteristics of the barrierlayer described above. For example, the outer layer can be formed suchthat it includes an inorganic material, such as a metal or a metalalloy. More particularly, the outer layer can include a transition metalelement. For example, in one certain embodiment, the outer layer caninclude nickel. In another embodiment, the outer layer can be formedsuch that it consists essentially of nickel.

In certain instances, the outer layer can be formed in the same manneras the inner layer, such as a deposition process. However, it is notnecessary that the outer layer be formed in the same manner as the innerlayer. In accordance with an embodiment, the outer layer can be formedthrough a deposition process including plating, spraying, printing,dipping, die coating, deposition, and a combination thereof. In certaininstances, the outer layer of the barrier layer can be formed atrelatively low temperatures, such as temperatures not greater than about400° C., not greater than about 375° C., not greater than about 350° C.,not greater than about 300° C., or even not greater than 250° C.According to one particular process, the outer layer can be formedthough a non-plating process, such as die coating. Moreover, theprocesses used to form the outer layer may include other methodsincluding for example heating, curing, drying, and a combinationthereof. It will be appreciated that formation of the outer layer insuch a manner may facilitate limiting the impregnation of unwantedspecies within the core and/or inner layer.

In accordance with an embodiment, the inner layer of the barrier layercan be formed to have a particular average thickness suitable for actingas a chemical barrier layer. For example, the barrier layer can have anaverage thickness of at least about 0.05 microns, such as least about0.1 microns, at least about 0.2 microns, at least about 0.3 micron, oreven at least about 0.5 microns. Still, the average thickness of theinner layer may be not greater than about 8 microns, such as not greaterthan about 7 microns, not greater than about 6 microns, not greater thanabout 5 microns, or even not greater than about 4 microns. It will beappreciated that the inner layer can have an average thickness within arange between any of the minimum and maximum thicknesses noted above.

The outer layer of the barrier layer can be formed to have a particularthickness. For example, in one embodiment the average thickness of theouter layer can be at least about 0.05 microns, such as least about 0.1microns, at least about 0.2 microns, at least about 0.3 micron, or evenat least about 0.5 microns. Still, in certain embodiments, the outerlayer can have an average thickness that is not greater than about 12microns, not greater than about 10 microns, not greater than about 8microns, not greater than about 7 microns, not greater than about 6microns, not greater than about 5 microns, not greater than about 4microns, or even not greater than about 3 microns. It will beappreciated that the outer layer of the barrier layer can have anaverage thickness within a range between any of the minimum and maximumthicknesses noted above.

Notably, in at least embodiment, the inner layer can be formed to have adifferent average thickness than the average thickness of the outerlayer. Such a design may facilitate improved impregnation resistance tocertain chemical species while also providing suitable bonding structurefor further processing. For example, in other embodiments the innerlayer can be formed to have an average thickness that is greater thanthe average thickness of the outer layer. However, in alternativeembodiments, the inner layer may be formed to have an average thicknessso that it is less than the average thickness of the outer layer.

According to one particular embodiment, the barrier layer can have athickness ratio [t_(i):t_(o)] between an average thickness of the innerlayer (t_(i)) and an average thickness of the outer layer (t_(o)) thatcan be within a range between about 3:1 and about 1:3. In otherembodiments, the thickness ratio can be within a range between about2.5:1 and about 1:2.5, such as within a range between about 2:1 andabout 1:2, within a range between about 1.8:1 and about 1:1.8, within arange between about 1.5:1 and about 1:1.5, or even within a rangebetween about 1.3:1 and about 1:1.3.

Notably, the barrier layer (including at least the inner layer and outerlayer) can be formed to have an average thickness that is not greaterthan about 10 microns. In other embodiments, the average thickness ofthe barrier layer may be less, such as not greater than about 9 microns,not greater than about 8 microns, not greater than about 7 microns, notgreater than about 6 microns, not greater than about 5 microns, or evennot greater than about 3 microns. Still, the average thickness of thebarrier layer can be at least about 0.05 microns, such as least about0.1 microns, at least about 0.2 microns, at least about 0.3 micron, oreven at least about 0.5 microns. It will be appreciated that the barrierlayer can have an average thickness within a range between any of theminimum and maximum thicknesses noted above.

Furthermore, the abrasive articles herein can form a substrate having acertain resistance to fatigue. For example, the substrates can have anaverage fatigue life of at least 300,000 cycles as measured through aRotary Beam Fatigue Test or a Hunter Fatigue Test. The test can be aMPIF Std. 56. The rotary beam fatigue test measures the number of cyclesup to wire break at designated stress (e.g. 700 MPa), i.e. constantstress or the stress under which the wire was not ruptured in a cyclicfatigue test with a number of repeating cycles of up to 10⁶ (e.g. stressrepresents fatigue strength). In other embodiments, the substrate maydemonstrate a higher fatigue life, such as least about 400,000 cycles,at least about 450,000 cycles, at least about 500,000 cycles, or even atleast about 540,000 cycles. Still, the substrate may have a fatigue lifethat is not greater than about 2,000,000 cycles.

After optionally providing a barrier layer at step 102, the process cancontinue at step 103, which includes forming a first layer overlying asurface of the substrate. The process of forming a first layer caninclude a deposition process, including for example, spraying, printing,dipping, die coating, plating, and a combination thereof. The firstlayer can be bonded directly to the external surface of the substrate.In fact, the first layer can be formed such that it overlies a majorityof the external surface of the substrate, and more particularly, canoverlie essentially the entire external surface of the substrate.

The first layer may be formed such that it is bonded to the substrate ina manner that it defines a bonding region. The bonding region can bedefined by an interdiffusion of elements between the first layer and thesubstrate. It will be appreciated that formation of the bonding regionmay not necessarily be formed at the moment when the first layer isdeposited on the surface of the substrate. For example, the formation ofa bonding region between the first layer and the substrate may be formedat a later time during processing, such as during a heat treatmentprocess to facilitate bonding between the substrate and other componentlayers formed on the substrate.

Alternatively, the first layer may be formed such that it directlycontacts at least a portion of the barrier layer, such as the exteriorperipheral surface of the barrier layer. In a particular embodiment, thefirst layer can be bonded directly to the barrier layer, and moreparticularly, bonded directly to an outer layer of the barrier layer. Asnoted above, the first layer may be formed such that it is bonded to thebarrier layer in a manner that it defines a bonding region. The bondingregion can be defined by an interdiffusion of elements between the firstlayer and the barrier layer. It will be appreciated that formation ofthe bonding region may not necessarily be formed at the moment when thefirst layer is deposited on the surface of the barrier layer. Forexample, the formation of a bonding region between the first layer andthe barrier may be formed at a later time during processing, such asduring a heat treatment process to facilitate bonding between thesubstrate and other component layers formed on the substrate.

Yet in another embodiment, it will be appreciated that the first layercan be made of material suitable for use as a first layer and a barrierlayer. For example, the first layer can have the same materials andconstruction of the barrier layer, facilitating improved mechanicalproperties of the substrate and may include a material of a first layerin any of the embodiments herein suitable for tacking and binding ofabrasive particles for further processing. The barrier layer can be adiscontinuous layer having coated regions and gaps in the barrier layer.The first layer can overlie the coated regions and the gaps in thebarrier layer where the underlying substrate may be exposed.

In one particular embodiment, the first layer can be disposed betweenthe substrate and other overlying layers, including for example, abonding layer, a coating layer, a layer of a first type of abrasiveparticles, a layer of a second type of abrasive particles, and acombination thereof. Moreover, it will be appreciated that the firstlayer can be disposed between the barrier layer and other overlyinglayers, including for example, a bonding layer, a coating layer, a layerof a first type of abrasive particles, a layer of a second type ofabrasive particles, and a combination thereof.

In accordance with an embodiment, the first layer can be formed from ametal, metal alloy, metal matrix composite, and a combination thereof.In one particular embodiment, the first layer can be formed of amaterial including a transition metal element. For example, the firstlayer can be a metal alloy including a transition metal element. Somesuitable transition metal elements can include, lead, silver, copper,zinc, indium, tin, titanium, molybdenum, chromium, iron, manganese,cobalt, niobium, tantalum, tungsten, palladium, platinum, gold,ruthenium, and a combination thereof. According to one particularembodiment, the first layer can be made of a metal alloy including tinand lead. In particular, such metal alloys of tin and lead may contain amajority content of tin as compared to lead, including but not limitedto, a tin/lead composition of at least about 60/40.

In another embodiment, the first layer can be made of a material havinga majority content of tin. In fact, in certain abrasive articles, thefirst layer may consist essentially of tin. The tin, alone or in thesolder, can have a purity of at least about 99%, such as at least about99.1%, at least about 99.2%, at least about 99.3%, at least about 99.4%,at least about 99.5%, at least about 99.6%, at least about 99.7%, atleast about 99.8%, or at least about 99.9%. In another aspect, the tincan have a purity of at least about 99.99%.

According to at least one embodiment, the first layer may be formed viaa plating process. The plating process may be an electrolyte platingprocess or an electroless plating process. In one particular instance,the first layer can be formed by traversing the substrate through acertain plating material, which can include a bath that can produce afirst layer comprising a matte tin layer. The matte tin layer can be aplated layer having particular features. For example, the matte tinlayer can have an organic content of not greater than about 0.5 wt % fora total weight of the plated material (i.e., the first layer). Organiccontent can include compositions include carbon, nitrogen, sulfur, and acombination thereof. In certain other instances, the content of organicmaterial in the matte tin layer can be not greater than about 0.3 wt %,such as not greater than about 0.1 wt %, not greater than about 0.08 wt%, or even not greater than about 0.05 wt % for the total weight of thefirst layer. According to one embodiment, the matte tin layer can beessentially free of organic brighteners and organic grain refiners.Moreover, the matte tin layer may have a purity of at least about 99.9%.

The matte tin layer may be made from a particular plating materialhaving certain features. For example, the plating material can have anorganic content of not greater than about 0.5 wt % for a total weight ofthe plated material in the bath. Organic content can includecompositions include carbon, nitrogen, sulfur, and a combinationthereof. In certain other instances, the content of organic material inthe plated material can be not greater than about 0.3 wt %, such as notgreater than about 0.1 wt %, not greater than about 0.08 wt %, or evennot greater than about 0.05 wt % for the total weight of the platingmaterial. According to one embodiment, the plating material can beessentially free of organic brighteners and organic grain refiners.Moreover, the plating material may have a purity of at least about99.9%.

Moreover, the matte tin layer may have a particular average grain sizeof tin material. For example, the matte tin layer can have an averagegrain size of at least about 0.1 microns, such as at least about 0.2microns, at least about 0.5 microns, or even at least about 1 micron.Still, in one non-limiting embodiment, the matte tin layer can have anaverage grain size of tin of not greater than about 50 microns, such asnot greater than about 25 microns, not greater than about 15 microns, ornot greater than about 10 microns. It will be appreciated that theaverage grain size of the grains of the matte tin layer can be within arange between any of the above minimum and maximum values.

In accordance with an embodiment, the first layer can be a soldermaterial. It will be appreciated that a solder material may include amaterial having a particular melting point, such as not greater thanabout 450° C. Solder materials are distinct from braze materials, whichgenerally have significantly higher melting points than soldermaterials, such as greater than 450° C., and more typically, greaterthan 500° C. Furthermore, brazing materials may have differentcompositions. In accordance with an embodiment, the first layer of theembodiments herein may be formed of a material having a melting point ofnot greater than about 400° C., such as not greater than about 375° C.,not greater than about 350° C., not greater than about 300° C., or notgreater than about 250° C. Still, the first layer may have a meltingpoint of at least about 100° C., such as at least about 125° C., atleast about 150° C., or even at least about 175° C. It will beappreciated that the first layer can have a melting point within a rangebetween any of the minimum and maximum temperatures noted above.

According to one embodiment, the first layer can include a same materialas the barrier layer, such that the compositions of the barrier layerand the first layer share at least one element in common. In yet analternative embodiment, the barrier layer and the first layer can beentirely different materials.

According to at least one embodiment, the formation of the first layercan include formation of additional layers overlying the first layer.For example, in one embodiment, the formation of the first layerincludes formation of an additional layer overlying the first layer tofacilitate further processing. The additional layer can be overlying thesubstrate, and more particularly, in direct contact with at least aportion of the first layer.

The additional layer can include a flux material, which facilitatesmelting of the material of the first layer and further facilitatesattachment of abrasive particles on the first layer. The flux materialcan be in the form of a generally uniform layer overlying the firstlayer, and more particularly, in direct contact with the first layer.The additional layer in the form of a flux material can comprise amajority content of flux material. In certain instances, essentially allof the additional layer can consist of the flux material.

The flux material can be in the form of a liquid or paste. According toone embodiment, the flux material can be applied to the first layerusing a deposition process such as spraying, dipping, painting,printing, brushing, and a combination thereof. For at least oneexemplary embodiment, the flux material can include a material such as achloride, an acid, a surfactant, a solvent, water and a combinationthereof. In one particular embodiment, the flux can includehydrochloride, zinc chloride, and a combination thereof.

After forming the first layer at step 103, the process can continue atstep 104 by placing abrasive particles on the first layer. Referenceherein to abrasive particles is reference to any one of the multipletypes of abrasive particle described herein, including for example afirst type of abrasive particle or a second type of abrasive particle.The types of abrasive particles are described in more detail herein. Insome instances, depending upon the nature of the process, the abrasiveparticles can be in direct contact with the first layer. Moreparticularly, the abrasive particles can be in direct contact with anadditional layer, such as a layer comprising a flux material, overlyingthe first layer. In fact, the additional layer of material comprisingthe flux material can have a natural viscosity and adhesivecharacteristic that facilitates holding the abrasive particles in placeduring processing, until further processes are conducted to permanentlybond the abrasive particles in place relative to the first layer.

Suitable methods of providing the abrasive particles on the first layer,and more particularly, on the additional layer comprising the fluxmaterial, can include various deposition methods, including but notlimited to, spraying, gravity coating, dipping, die coating, dipcoating, electrostatic coating, plating, and a combination thereof.Particularly useful methods of applying the abrasive particles caninclude a spraying process, conducted to apply a substantially uniformcoating of abrasive particles onto the additional layer comprising theflux material.

In an alternative embodiment, the process of providing the abrasiveparticles can include the formation of a mixture comprising theadditional material, which may include a flux material and the abrasiveparticles. In one particular process according to an embodiment herein,the process of providing the abrasive particles can include dip coatingthe abrasive particles on the tacking film. Dip coating can includetranslating the abrasive article through a mixture or slurry comprisingat least the flux material and the abrasive particles. As such, theabrasive particles can be applied to the first layer and the additionallayer comprising the flux material can be formed simultaneously.

According to one particular embodiment, the process of applying theadditional coating, which may optionally include simultaneousapplication of the abrasive particles, depending upon the components ofthe mixture, can include a die coating process. In certain instances,the abrasive article can be translated through a mixture comprising theadditional material (and optionally the abrasive particles) andtranslated through a mechanism (e.g., a die opening having controlleddimensions) to control the thickness of the additional layer.

According to an embodiment, particular aspects of the slurry and the dipcoating process may be controlled to facilitate the formation of asuitable abrasive article. For example, in one embodiment the slurry canbe a Newtonian fluid having a viscosity of at least 0.1 mPa s and nomore than 1 Pa s at a temperature of 25° C. and a shear rate of 1 l/s.The slurry can also be a non-Newtonian fluid having a viscosity of atleast 1 mPa s and no more than 100 Pa s, or even not greater than about10 Pa s, at the shear rate of 10 l/s as measured at a temperature of 25°C. Viscosity can be measured using a TA Instruments AR-G2 rotationalrheometer using a set up of 25 mm parallel plates, a gap ofapproximately 2 mm, shear rates of 0.1 to 10 l/s at a temperature of 25°C.

The process of providing the abrasive particles may also includecontrolling the abrasive particle concentration (e.g., the firstabrasive particle concentration, the second abrasive particleconcentration, or a combination of first and second abrasiveconcentrations). Controlling the abrasive particle concentration caninclude at least one of controlling an amount of abrasive particlesdelivered to the first layer, a ratio of the amount of abrasiveparticles relative to an amount of the first layer, a ratio of theamount of abrasive particles relative to an amount of an additionallayer comprising the flux material, a ratio of the amount of abrasiveparticles relative to the viscosity of the slurry, a position of theabrasive particles on the first layer, a position of the first type ofabrasive particle on the first layer relative to a location of a secondtype of abrasive particle, a force of delivering the abrasive particles,and a combination thereof. In particular instances, controlling theabrasive particle concentration can include measuring the abrasiveparticle concentration during forming. Various methods of measuring canbe used including mechanical, optical, and a combination thereof.Additionally, in certain embodiments, the process of controlling theabrasive particle concentration can include measuring the distributionof the abrasive particles on the substrate during forming the abrasivearticle and adjusting the amount of the abrasive particles deposited onthe first layer based on a measured value. In an exemplary embodiment,the process of adjusting the amount of abrasive particles deposited onthe substrate can include changing a deposition parameter based on themeasured value, including for example, in the context of providing theabrasive particles via a spraying process, adjusting the processparameters of the spray nozzle (e.g., force of material being ejected,weight ratio of abrasive particles to other components, etc.). Somesuitable examples of deposition parameters can include weight ratio ofabrasive particles to carrier material (e.g., flux), delivery force usedto apply abrasive particles, temperature, content of organics in carriermaterial or on substrate, atmospheric conditions of forming environment,and the like.

For at least one embodiment, the process of depositing the abrasiveparticles onto the first layer can include deposition, which moreparticularly can include spraying the abrasive particles onto the firstlayer. In certain processes, spraying can include using more than onenozzle. In more particular designs, more than one nozzle for delivery ofthe abrasive particles can be used, wherein the nozzles are arrangedaround the substrate in axis-symmetrical pattern.

Alternatively, the process of depositing the abrasive particles on thefirst layer can include translating the abrasive article having thefirst layer through a bed of abrasive particles. In certain instances,the bed can be a fluidized bed of abrasive particles.

Reference herein to abrasive particles can include reference to multipletypes of abrasive particles, including for example, a first type ofabrasive particle and a second type of abrasive particle different thanthe first type. According to at least one embodiment, the first type ofabrasive particle can be different than the second type of abrasiveparticle based on at least one particle characteristic of the groupconsisting of hardness, friability, toughness, particle shape,crystalline structure, average particle size, composition, particlecoating, grit size distribution, and a combination thereof. Moreover, itwill be appreciated that reference herein to abrasive particles caninclude agglomerated particles including a binder phase, unagglomeratedparticles, and a combination thereof, including for instance, a firsttype that is an agglomerated particle and a second type that is anunagglomerated particle.

The first type of abrasive particle can include a material such as anoxide, a carbide, a nitride, a boride, an oxynitride, an oxyboride,diamond, and a combination thereof. In certain embodiments, the firsttype of abrasive particle can incorporate a superabrasive material. Forexample, one suitable superabrasive material includes diamond. Inparticular instances, the first type of abrasive particle can consistessentially of diamond.

Moreover, the second type of abrasive particle can include a materialsuch as an oxide, a carbide, a nitride, a boride, an oxynitride, anoxyboride, diamond, and a combination thereof. In certain embodiments,the second type of abrasive particle can incorporate a superabrasivematerial. For example, one suitable superabrasive material includesdiamond. In particular instances, the second type of abrasive particlecan consist essentially of diamond.

In one embodiment, the first type of abrasive particle can include amaterial having a Vickers hardness of at least about 10 GPa. In otherinstances, the first type of abrasive particle can have a Vickershardness of at least about 25 GPa, such as at least about 30 GPa, atleast about 40 GPa, at least about 50 GPa, or even at least about 75GPa. Still, in at least one non-limiting embodiment, the first type ofabrasive particle can have a Vickers hardness that is not greater thanabout 200 GPa, such as not greater than about 150 GPa, or even notgreater than about 100 GPa. It will be appreciated that the first typeof abrasive particle can have a Vickers hardness within a range betweenany of the minimum and maximum values noted above.

The second type of abrasive particle can include a material having aVickers hardness of at least about 10 GPa. In other instances, thesecond type of abrasive particle can have a Vickers hardness of at leastabout 25 GPa, such as at least about 30 GPa, at least about 40 GPa, atleast about 50 GPa, or even at least about 75 GPa. Still, in at leastone non-limiting embodiment, the second type of abrasive particle canhave a Vickers hardness that is not greater than about 200 GPa, such asnot greater than about 150 GPa, or even not greater than about 100 GPa.It will be appreciated that the second type of abrasive particle canhave a Vickers hardness within a range between any of the minimum andmaximum values noted above.

In certain instances, the first type of abrasive particle can have afirst average hardness (H1) and the second type of abrasive particle canhave a second average hardness (H2) that is different than the firstaverage hardness. In some examples, the first average hardness can begreater than the second average hardness. In still other instances, thefirst average hardness can be less than the second average hardness.According to yet another embodiment, the first average hardness can besubstantially the same as the second average hardness.

For at least one aspect, the first average hardness can be at leastabout 5% different than the second average hardness based on theabsolute value of the equation ((H1−H2)/H1)×100%. In one embodiment, thefirst average hardness is at least about 10% different, at least about20% different, at least about 30% different, at least about 40%different, at least about 50% different, at least about 60% different,at least about 70% different, at least about 80% different, or even atleast about 90% different than the second average hardness. Yet, inanother non-limiting embodiment, the first average hardness may be notgreater than about 99% different, such as not greater than about 90%different, not greater than about 80% different, not greater than about70% different, not greater than about 60% different, not greater thanabout 50% different, not greater than about 40% different, not greaterthan about 30% different, not greater than about 20% different, notgreater than about 10% different than the second average hardness. Itwill be appreciated that the difference between the first averagehardness and the second average hardness can be within a range betweenany of the above minimum and maximum percentages.

In at least one embodiment, the first type of abrasive particle can havea first average particle size (P1) different than a second averageparticle size (P2) of the second type of abrasive particle. In someinstances, the first average particle size can be greater than thesecond average particle size. In still other embodiment, the firstaverage particle size can be less than the second average particle size.According to yet another embodiment, the first average particle size canbe substantially the same as the second average particle size.

For a particular embodiment, the first type of abrasive particle canhave a first average particle size (P1) and the second type of abrasiveparticle can have a second average particle size (P2), wherein the firstaverage particle size is at least about 5% different than the secondaverage particle size based on the absolute values of the equation((P1−P2)/P1)×100%. In one embodiment, the first average particle size isat least about 10% different, such as at least about 20% different, atleast about 30% different, at least about 40% different, at least about50% different, at least about 60% different, at least about 70%different, at least about 80% different, or even at least about 90%different than the second average particle size. Yet, in anothernon-limiting embodiment, the first average particle size may be notgreater than about 99% different, such as not greater than about 90%different, not greater than about 80% different, not greater than about70% different, not greater than about 60% different, not greater thanabout 50% different, not greater than about 40% different, not greaterthan about 30% different, not greater than about 20% different, notgreater than about 10% different than the second average particle size.It will be appreciated that the difference between the first averageparticle size and the second average particle size can be within a rangebetween any of the above minimum and maximum percentages.

According to at least one embodiment, the first type of abrasiveparticle can have a first average particle size of not greater thanabout 500 microns, such as not greater than about 300 microns, notgreater than about 200 microns, not greater than about 150 microns, oreven not greater than about 100 microns. Yet, in a non-limitingembodiment, the first type of abrasive particle may have a first averageparticle size of at least about 0.1 microns, such as at least about 0.5microns, at least about 1 micron, at least about 2 microns, at leastabout 5 microns, or even at least about 8 microns. It will beappreciated that the first average particle size can be within a rangebetween any of the above minimum and maximum percentages.

For certain embodiments, the second type of abrasive particle can have asecond average particle size of not greater than about 500 microns, suchas not greater than about 300 microns, not greater than about 200microns, not greater than about 150 microns, or even not greater thanabout 100 microns. Yet, in a non-limiting embodiment, the second type ofabrasive particle may have a second average particle size of at leastabout 0.1 microns, such as at least about 0.5 microns, at least about 1micron, at least about 2 microns, at least about 5 microns, or even atleast about 8 microns. It will be appreciated that the second averageparticle size can be within a range between any of the above minimum andmaximum percentages.

For a particular embodiment, the first type of abrasive particle canhave a first average friability (F1) and the second type of abrasiveparticle can have a second average friability (F2). Moreover, the firstaverage friability can be different than the second average friability,including greater than or less than the second average friability.Still, in another embodiment, the first average friability can besubstantially the same as the second average friability.

According to one embodiment, the first average friability can be atleast about 5% different than the second average friability based on theabsolute values of the equation ((F1−F2)/F1)×100%. In one embodiment,the first average friability is at least about 10% different, such as atleast about 20% different, at least about 30% different, at least about40% different, at least about 50% different, at least about 60%different, at least about 70% different, at least about 80% different,or even at least about 90% different than the second average friability.Yet, in another non-limiting embodiment, the first average friabilitymay be not greater than about 99% different, such as not greater thanabout 90% different, not greater than about 80% different, not greaterthan about 70% different, not greater than about 60% different, notgreater than about 50% different, not greater than about 40% different,not greater than about 30% different, not greater than about 20%different, not greater than about 10% different than the second averagefriability. It will be appreciated that the difference between the firstaverage friability and the second average friability can be within arange between any of the above minimum and maximum percentages.

For a particular embodiment, the first type of abrasive particle canhave a first average toughness (T1) and the second type of abrasiveparticle can have a second average toughness (T2). Moreover, the firstaverage toughness can be different than the second average toughness,including greater than or less than the second average toughness. Still,in another embodiment, the first average toughness can be substantiallythe same as the second average toughness.

According to one embodiment, the first average toughness can be at leastabout 5% different than the second average toughness based on theabsolute values of the equation ((T1−T2)/T1)×100%. In one embodiment,the first average toughness is at least about 10% different, such as atleast about 20% different, at least about 30% different, at least about40% different, at least about 50% different, at least about 60%different, at least about 70% different, at least about 80% different,or even at least about 90% different than the second average toughness.Yet, in another non-limiting embodiment, the first average toughness maybe not greater than about 99% different, such as not greater than about90% different, not greater than about 80% different, not greater thanabout 70% different, not greater than about 60% different, not greaterthan about 50% different, not greater than about 40% different, notgreater than about 30% different, not greater than about 20% different,not greater than about 10% different than the second average toughness.It will be appreciated that the difference between the first averagetoughness and the second average toughness can be within a range betweenany of the above minimum and maximum percentages.

Particular abrasive articles of the embodiments herein may utilizeparticular contents of the first type of abrasive particle and thesecond type of abrasive particle relative to each other, which mayfacilitate improved performance. For example, the first type of abrasiveparticle can be present in a first content and the second type ofabrasive particle may be present in a second content. According to oneembodiment, the first content can be greater than the second content.Yet, in other instances, the second content can be greater than thefirst content. For still another embodiment, the first content can besubstantially the same as the second content.

In at least one embodiment, the first type of abrasive particle can bepresent in a first content and the second type of abrasive particle canbe present in a second content, and the relative amount of the firstcontent to the second content based upon a numerical particle count candefine a particle count ratio (FC:SC), wherein FC represents the firstparticle count content and SC represents the second particle countcontent. According to one embodiment, the particle count ratio (FC:SC)can be not greater than about 100:1, such as not greater than about50:1, not greater than about 20:1, not greater than about 10:1, notgreater than about 5:1, or even not greater than about 2:1. In oneparticular instance, the particle count ratio (FC:SC) can beapproximately 1:1, such that the first content and second content (basedon particle count) are substantially the same or essentially the same.Still, in another non-limiting embodiment, the particle count ratio(FC:SC) can be at least about 2:1, such as at least about 5:1, at leastabout 10:1, at least about 20:1, at least about 50:1, at least about100:1. It will be appreciated that the particle count ratio can bedefined by a range between any two ratios noted above.

According to another embodiment, the particle count ratio (FC:SC) can benot greater than about 1:100, such as not greater than about 1:50, notgreater than about 1:20, not greater than about 1:10, not greater thanabout 1:5, not greater than about 1:2. Still, in another non-limitingembodiment, the particle count ratio (FC:SC) can be at least about 1:2,such as at least about 1:5, at least about 1:10, at least about 1:20, atleast about 1:50, at least about 1:100. It will be appreciated that theparticle count ratio can be defined by a range between any two ratiosnoted above. For example, the particle count ratio can be between 1:1and 1:100, such as between about 1:2 and 1:100. In other instances, theparticle count ratio may between 100:1 and 1:1, or even between about100:1 and 2:1. Still, in a non-limiting embodiment, the particle countratio may be between about 100:1 and 1:100, such as between about 50:1and 1:50, such as between about 20:1 and 1:20, between about 10:1 and1:10, between about 5:1 and 1:5, or even between about 2:1 and 1:2.

The content of the first type of abrasive particle and the second typeof abrasive particle may be measured in another manner besides theparticle count. For example, the first type of abrasive particle can bemeasured by a weight percent of the first type of abrasive particle forthe total content of abrasive particles (P1 wt %) and the second type ofabrasive particle can be measured by the weight percent of the secondtype of abrasive particle for the total content of abrasive particles(P2 wt %). According to one embodiment, the abrasive article can have aparticle weight ratio (P1 wt %:P2 wt %), as defined by the relativeweight percent of the first type of abrasive particle to the weightpercent of the second type of abrasive particle. In one particularembodiment, the particle weight ratio can be not greater than about100:1, such as not greater than about 50:1, not greater than about 20:1,not greater than about 10:1, not greater than about 5:1, not greaterthan about 2:1. Still, in one instance, the particle weight ratio (P1 wt%:P2 wt %) can be approximately 1:1, such that the first content andsecond content (based on weight percent) are substantially the same oressentially the same. Still, in another non-limiting embodiment, theparticle weight ratio (P1 wt %:P2 wt %) can be at least about 2:1, suchas at least about 5:1, at least about 10:1, at least about 20:1, atleast about 50:1, at least about 100:1. It will be appreciated that theparticle weight ratio (P1 wt %:P2 wt %) can be defined by a rangebetween any two ratios noted above.

According to another embodiment, the particle weight ratio (P1 wt %:P2wt %) can be not greater than about 1:100, such as not greater thanabout 1:50, not greater than about 1:20, not greater than about 1:10,not greater than about 1:5, not greater than about 1:2. Still, inanother non-limiting embodiment, the particle weight ratio (P1 wt %:P2wt %) can be at least about 1:2, such as at least about 1:5, at leastabout 1:10, at least about 1:20, at least about 1:50, at least about1:100. It will be appreciated that the particle weight ratio (P1 wt %:P2wt %) can be defined by a range between any two ratios noted above. Forexample, the particle weight ratio (P1 wt %:P2 wt %) can be between 1:1and 1:100, such as between about 1:2 and 1:100. In other instances, theparticle weight ratio (P1 wt %:P2 wt %) may between 100:1 and 1:1, oreven between about 100:1 and 2:1. Still, in a non-limiting embodiment,the particle weight ratio (P1 wt %:P2 wt %) may be between about 100:1and 1:100, such as between about 50:1 and 1:50, such as between about20:1 and 1:20, between about 10:1 and 1:10, between about 5:1 and 1:5,or even between about 2:1 and 1:2.

The first type of abrasive particle can have a particular shape, such asa shape from the group including elongated, equiaxed, ellipsoidal, boxy,rectangular, triangular, irregular, and the like. The second type ofabrasive particle may also have a particular shape, including forexample, elongated, equiaxed, ellipsoidal, boxy, rectangular,triangular, and the like. It will be appreciated that the shape of thefirst type of abrasive particle can be different than the shape of thesecond type of abrasive particle. Alternatively, the first type ofabrasive particle can have a shape that is substantially the same as thesecond type of abrasive particle.

Moreover, in certain instances, the first type of abrasive particle canhave a first type of crystalline structure. Some exemplary crystallinestructures can include multicrystalline, monocrystalline, polygonal,cubic, hexagonal, tetrahedral, octagonal, complex carbon structure(e.g., Bucky-ball), and a combination thereof. Additionally, the secondtype of abrasive particle can have a particular crystalline structure,such as multicrystalline, monocrystalline, cubic, hexagonal,tetrahedral, octagonal, a complex carbon structure (e.g., Bucky-ball),and a combination thereof. It will be appreciated that the crystallinestructure of the first type of abrasive particle can be different thanthe crystalline structure of the second type of abrasive particle.Alternatively, the first type of abrasive particle can have acrystalline structure that is substantially the same as the second typeof abrasive particle.

For a particular embodiment, the first type of abrasive particle can bedefined by a wide grit size distribution, wherein at least 80% of thefirst type of abrasive particle has an average particle size containedwithin a range of at least about 30 microns over a range of averageparticle sizes between about 1 micron to about 100 microns.Additionally, the second type of abrasive particle may also be definedby a wide grit size distribution wherein at least 80% of the second typeof abrasive particle has an average particle size contained within arange of at least about 30 microns over a range of average particlesizes between about 1 micron to about 100 microns.

In one embodiment, the wide grit size distribution can be a bimodalparticle size distribution, wherein the bimodal particle sizedistribution comprises a first mode defining a first median particlesize (M1) and a second mode defining a second median particle size (M2)that is different than the first median particle size. According to aparticular embodiment, the first median particle size and second medianparticle size are at least 5% different based on the equation((M1−M2)/M1)×100%. In still other embodiments, the first median particlesize and the second median particle size can be at least about 10%different, such as at least about 20% different, at least about 30%different, at least about 40% different, at least about 50% different,at least about 60% different, at least about 70% different, at leastabout 80% different, or even at least about 90% different. Yet, inanother non-limiting embodiment, the first median particle size may benot greater than about 99% different, such as not greater than about 90%different, not greater than about 80% different, not greater than about70% different, not greater than about 60% different, not greater thanabout 50% different, not greater than about 40% different, not greaterthan about 30% different, not greater than about 20% different, or evennot greater than about 10% different than the second median particlesize. It will be appreciated that the difference between the firstmedian particle size and the second median particle size can be within arange between any of the above minimum and maximum percentages.

For a particular embodiment, the first type of abrasive particle caninclude an agglomerated particle. More particularly, the first type ofabrasive particle can consist essentially of an agglomerated particle.Moreover, the second type of abrasive particle may include anunagglomerated particle, and more particularly, may consist essentiallyof an unagglomerated particle. Still, it will be appreciated that thefirst and second type of abrasive particles may include an agglomeratedparticle or an unagglomerated particle. The first type of abrasiveparticle can be an agglomerated particle having a first average particlesize and the second type of abrasive particle including anunagglomerated particle having a second average particle size differentthan the first average particle size. Notably, for one embodiment, thesecond average particle size can be substantially the same as the firstaverage particle size.

According to an embodiment, an agglomerated particle can includeabrasive particles bonded to each other by a binder material. Somesuitable examples of a binder material can include an inorganicmaterial, an organic material, and a combination thereof. Moreparticularly, the binder material may be a ceramic, a metal, a glass, apolymer, a resin, and a combination thereof. In at least one embodiment,the binder material can be a metal or metal alloy, which may include oneor more transition metal elements. According to an embodiment, thebinder material can include at least one metal element from a componentlayer of the abrasive article, including for example, the barrier layer,the first layer, the bonding layer, the coating layer, and a combinationthereof. For at least one abrasive article herein, at least a portion ofthe binder material can be the same material as used in the first layer,and more particularly, essentially all of the binder material can be thesame material of the first layer. In yet another aspect, at least aportion of the binder material can be the same material as a bondinglayer overlying the abrasive particles, and more particularly,essentially all of the binder material can be the same as the bondinglayer.

In a more particular embodiment, the binder can be a metal material thatincludes at least one active binding agent. The active binding agent maybe an element or composition including a nitride, a carbide, andcombination thereof. One particular exemplary active binding agent caninclude a titanium-containing composition, a chromium-containingcomposition, a nickel-containing composition, a copper-containingcomposition and a combination thereof.

In another embodiment, the binder material can include a chemical agentconfigured to chemically react with a workpiece in contact with theabrasive article to facilitate a chemical removal process on the surfaceof the workpiece while the abrasive article is also conducting amechanical removal process. Some suitable chemical agents can includeoxides, carbides, nitrides, an oxidizer, pH modifier, surfactant, and acombination thereof.

The agglomerated particle of embodiments herein can include a particularcontent of abrasive particles, a particular content of binder material,and a particular content of porosity. For example, the agglomeratedparticle can include a greater content of abrasive particle than acontent of binder material. Alternatively, the agglomerated particle caninclude a greater content of binder material than a content of abrasiveparticle. For example, in one embodiment, the agglomerated particle caninclude at least about 5 vol % abrasive particle for the total volume ofthe agglomerated particle. In other instances, the content of abrasiveparticles for the total volume of the agglomerated particle can begreater, such as at least about 10 vol %, such as at least about 20 vol%, at least about 30 vol %, at least about 40 vol %, at least about 50vol %, at least about 60 vol %, at least about 70 vol %, at least about80 vol %, or even at least about 90 vol %. Yet, in another non-limitingembodiment, the content of abrasive particles in an agglomeratedparticle for the total volume of the agglomerated particle can be notgreater than about 95 vol %, such as not greater than about 90 vol %,not greater than about 80 vol %, not greater than about 70 vol %, notgreater than about 60 vol %, not greater than about 50 vol %, notgreater than about 40 vol %, not greater than about 30 vol %, notgreater than about 20 vol %, or even not greater than about 10 vol %. Itwill be appreciated that the content of the abrasive particles in theagglomerated particle can be within a range between any of the aboveminimum and maximum percentages.

According to another aspect, the agglomerated particle can include atleast about 5 vol % binder material for the total volume of theagglomerated particle. In other instances, the content of bindermaterial for the total volume of the agglomerated particle can begreater, such as at least about 10 vol %, such as at least about 20 vol%, at least about 30 vol %, at least about 40 vol %, at least about 50vol %, at least about 60 vol %, at least about 70 vol %, at least about80 vol %, or even at least about 90 vol %. Yet, in another non-limitingembodiment, the content of binder material in an agglomerated particlefor the total volume of the agglomerated particle can be not greaterthan about 95 vol %, such as not greater than about 90 vol %, notgreater than about 80 vol %, not greater than about 70 vol %, notgreater than about 60 vol %, not greater than about 50 vol %, notgreater than about 40 vol %, not greater than about 30 vol %, notgreater than about 20 vol %, or even not greater than about 10 vol %. Itwill be appreciated that the content of the binder material in theagglomerated particle can be within a range between any of the aboveminimum and maximum percentages.

In yet another aspect, the agglomerated particle can include aparticular content of porosity. For example, the agglomerated particlecan include at least about 1 vol % porosity for the total volume of theagglomerated particle. In other instances, the content of porosity forthe total volume of the agglomerated particle can be greater, such as atleast about 5 vol %, at least about 10 vol %, at least about 20 vol %,at least about 30 vol %, at least about 40 vol %, at least about 50 vol%, at least about 60 vol %, at least about 70 vol %, or even at leastabout 80 vol %. Yet, in another non-limiting embodiment, the content ofporosity in an agglomerated particle for the total volume of theagglomerated particle can be not greater than about 90 vol %, notgreater than about 80 vol %, not greater than about 70 vol %, notgreater than about 60 vol %, not greater than about 50 vol %, notgreater than about 40 vol %, not greater than about 30 vol %, notgreater than about 20 vol %, or even not greater than about 10 vol %. Itwill be appreciated that the content of the porosity in the agglomeratedparticle can be within a range between any of the above minimum andmaximum percentages.

The porosity within the agglomerated particle can be of various types.For example, the porosity can be closed porosity, generally defined bydiscrete pores that are spaced apart from each other within the volumeof the agglomerated particle. In at least one embodiment, a majority ofthe porosity within the agglomerated particle can be closed porosity.Alternatively, the porosity can be open porosity, defining a network ofinterconnected channels extending through the volume of the agglomeratedparticle. In certain instances, a majority of the porosity can be openporosity.

The agglomerated particle can be sourced from a supplier. Alternatively,the agglomerated particle may be formed prior to the formation of theabrasive article. Suitable processes for forming the agglomeratedparticle can include screening, mixing, drying, solidifying, electrolessplating, electrolyte plating, sintering, brazing, spraying, printing,and a combination thereof.

According to one particular embodiment, the agglomerated particle can beformed in-situ with the formation of the abrasive article. For example,the agglomerated particle may be formed while forming the first layer orwhile forming a bonding layer over the first layer. Suitable processesfor forming the agglomerated particle in-situ with the abrasive articlecan include a deposition process. Particular deposition processes caninclude, but are not limited to, plating, electroplating, dipping,spraying, printing, coating, gravity coating, and a combination thereof.In at least one particular embodiment, the process of forming theagglomerated particle comprises simultaneously forming a bonding layerand the agglomerated particle via a plating process.

Still, according to another embodiment, any of the abrasive particles,including the first type or second type can be placed on the abrasivearticle during the formation of the bonding layer. The abrasiveparticles may be deposited on the first layer with the bonding layer viaa deposition process. Some suitable exemplary deposition processes caninclude spraying, gravity coating, electroless plating, electrolyteplating, dipping, die coating, electrostatic coating, and a combinationthereof,

According to at least one embodiment, the first type of abrasiveparticle can have a first particle coating. Notably, the first particlecoating layer can overlie the exterior surface of the first type ofabrasive particle, and more particularly, may be in direct contact withthe exterior surface of the first type of abrasive particle. Suitablematerials for use as the first particle coating layer can include ametal or metal alloy. In accordance with one particular embodiment, thefirst particle coating layer can include a transition metal element,such as titanium, vanadium, chromium, molybdenum, iron, cobalt, nickel,copper, silver, zinc, manganese, tantalum, tungsten, and a combinationthereof. One certain first particle coating layer can include nickel,such as a nickel alloy, and even alloys having a majority content ofnickel, as measured in weight percent as compared to other speciespresent within the first particle coating layer. In more particularinstances, the first particle coating layer can include a single metalspecies. For example, the first particle coating layer can consistessentially of nickel. The first particle film layer can be a platedlayer, such that it may be an electrolyte plated layer and anelectroless plated layer.

The first particle coating layer can be formed to overlie at least aportion of the exterior surface of the first type of abrasive particle.For example, the first particle coating layer may overly at least about50% of the exterior surface area of the abrasive particle. In otherembodiments, the coverage of the first particle coating layer can begreater, such as at least about 75%, at least about 80%, at least about90%, at least about 95%, or essentially the entire exterior surface ofthe first type of abrasive particle.

The first particle coating layer may be formed to have a particularcontent relative to the amount of the first type of abrasive particle tofacilitate processing. For example, the first particle coating layer canbe at least about 5% of the total weight of each of the first type ofabrasive particle. In other instances, the relative content of the firstparticle coating layer to the total weight of each of the first type ofabrasive particle can be greater, such as at least about 10%, at leastabout 20%, at least about 30%, at least about 40%, at least about 50%,at least about 60%, at least about 70%, or even at least about 80%. Yet,in another non-limiting embodiment, the relative content of the firstparticle coating layer to the total weight of each of the first type ofabrasive particle may be not greater than about 100%, such as notgreater than about 90%, not greater than about 80%, not greater thanabout 70%, not greater than about 60%, not greater than about 50%, notgreater than about 40%, not greater than about 30%, not greater thanabout 20%, or even not greater than about 10%. It will be appreciatedthat the relative content of the first particle coating layer to thetotal weight of each of the first type of abrasive particle can bewithin a range between any of the minimum and maximum percentages notedabove.

According to one embodiment, the first particle coating layer can beformed to have a particular thickness suitable to facilitate processing.For example, the first particle coating layer can have an averagethickness of not greater than about 5 microns, such as not greater thanabout 4 microns, not greater than about 3 microns, or even not greaterthan about 2 microns. Still, according to one non-limiting embodiment,the first particle coating layer can have an average thickness of atleast about 0.01 microns, 0.05 microns, at least about 0.1 microns, oreven at least about 0.2 microns. It will be appreciated that the averagethickness of the first particle coating layer can be within a rangebetween any of the minimum and maximum values noted above.

According to certain aspects herein, the first particle coating layercan be formed of a plurality of discrete film layers. For example, thefirst particle coating layer can include a first particle film layeroverlying the first type of abrasive particle, and a second particlefilm layer different than the first particle film layer overlying thefirst particle film layer. The first particle film layer may be indirect contact with an exterior surface of the first type of abrasiveparticle and the second particle film layer may be in direct contactwith the first particle film layer.

In at least one aspect, the second particle film layer overlies at leastabout 50% of an exterior surface area of the first particle film layeron the first type of abrasive particle. In other instances, the secondparticle film overlies a greater surface area, such as at least about75%, at least about 90%, or even essentially the entire exterior surfacearea of the first particle film layer of the first type of abrasiveparticle.

The first particle film layer can include any of the materials notedherein for the first particle coating layer, including for example, ametal, a metal alloy, and a combination thereof. In some instances, thefirst particle film layer may include a transition metal element, andmore particularly, a metal such as titanium, vanadium, chromium,molybdenum, iron, cobalt, nickel, copper, silver, zinc, manganese,tantalum, tungsten, and a combination thereof. The first particle filmlayer may include a majority content of nickel, such that in someinstances, the first particle film layer consists essentially of nickel.In yet another embodiment, the first particle film layer may consistessentially of copper.

The second particle film layer can include any of the materials notedherein for the first particle coating layer, including for example, ametal, a metal alloy, metal matrix composites, and a combinationthereof. The second particle film layer may include the same material asthe first particle film layer. However, in at least one embodiment, thesecond particle film layer includes a different material, and notably,may be completely distinct in composition from the first particle filmlayer. In some instances, the second particle film layer may include atransition metal element, and more particularly, a metal such as lead,silver, copper, zinc, tin, titanium, molybdenum, chromium, iron,manganese, cobalt, niobium, tantalum, tungsten, palladium, platinum,gold, ruthenium, and a combination thereof. The second particle filmlayer may include a majority content of tin, such that in someinstances, the second particle film layer consists essentially of tin.In yet another embodiment, the second particle film layer may include ametal alloy of tin.

The second particle film layer may include a low temperature metal alloy(LTMA) material. The LTMA material can have a melting point of notgreater than about 450° C., such as not greater than about 400° C., notgreater than about 375° C., not greater than about 350° C., not greaterthan about 300° C., or even not greater than about 250° C. Still,according to at least one non-limiting embodiment, the LTMA material canhave a melting point of at least about 100° C., such as at least about125° C., or even at least about 150° C. It will be appreciated that themelting point of the LTMA material can be within a range between any ofthe minimum and maximum values noted above.

The first particle film layer can have an average thickness that isdifferent than the average thickness of the second particle film layer.For example, in some instances, the first particle film layer can havean average thickness that is greater than the average thickness of thesecond particle film layer. In yet another embodiment, the firstparticle film layer can have an average thickness less than an averagethickness of the second particle film layer. Still, in at least onenon-limiting embodiment, the first particle film layer can have anaverage thickness substantially equal to the average thickness of thesecond particle film layer.

The first particle film layer may be present in a particular relativeamount compared to the total weight of each of the first type ofabrasive particle. For example, the relative content of the firstparticle film layer to the total weight of each of the first type ofabrasive particle can be at least about 5%, such as at least about 10%,at least about 20%, at least about 30%, at least about 40%, at leastabout 50%, at least about 60%, at least about 70%, or even at leastabout 80%. Yet, in another non-limiting embodiment, the relative contentof the first particle film layer to the total weight of each of thefirst type of abrasive particle may be not greater than about 100%, suchas not greater than about 90%, not greater than about 80%, not greaterthan about 70%, not greater than about 60%, not greater than about 50%,not greater than about 40%, not greater than about 30%, not greater thanabout 20%, or even not greater than about 10%. It will be appreciatedthat the relative content of the first particle film layer to the totalweight of each of the first type of abrasive particle can be within arange between any of the minimum and maximum percentages noted above.

The second particle film layer may be present in a particular relativeamount compared to the total weight of each of the first type ofabrasive particle and the first particle film layer. For example, therelative content of the second particle film layer to the total weightof each of the first type of abrasive particle and the first particlefilm layer can be at least about 5%, such as at least about 10%, atleast about 20%, at least about 30%, at least about 40%, at least about50%, at least about 60%, at least about 70%, or even at least about 80%.Yet, in another non-limiting embodiment, the relative content of thesecond particle film layer to the total weight of each of the first typeof abrasive particle and the first particle film layer may be notgreater than about 200%, such as not greater than about 150%, notgreater than about 120%, not greater than about 100%, not greater thanabout 80%, not greater than about 60%, not greater than about 50%, notgreater than about 40%, not greater than about 30%, or even not greaterthan about 20%. It will be appreciated that the relative content of thesecond particle film layer to the total weight of each of the first typeof abrasive particle and the first particle film layer can be within arange between any of the minimum and maximum percentages noted above.

According to one embodiment, the first particle film layer can be formedto have a particular thickness suitable to facilitate processing. Forexample, the first particle film layer can have an average thickness ofnot greater than about 5 microns, such as not greater than about 4microns, not greater than about 3 microns, or even not greater thanabout 2 microns. Still, according to one non-limiting embodiment, thefirst particle film layer can have an average thickness of at leastabout 0.01 microns, 0.05 microns, at least about 0.1 microns, or even atleast about 0.2 microns. It will be appreciated that the averagethickness of the first particle film layer can be within a range betweenany of the minimum and maximum values noted above.

According to one embodiment, the second particle film layer can beformed to have a particular thickness suitable to facilitate processing.For example, the second particle film layer can have an averagethickness of not greater than about 5 microns, such as not greater thanabout 4 microns, not greater than about 3 microns, or even not greaterthan about 2 microns. Still, according to one non-limiting embodiment,the second particle film layer can have an average thickness of at leastabout 0.05 microns, 0.1 microns, at least about 0.3 microns, or even atleast about 0.5 microns. It will be appreciated that the averagethickness of the second particle film layer can be within a rangebetween any of the minimum and maximum values noted above.

In yet another aspect, the first particle film layer can be formed tohave a particular thickness relative to the first average particle sizeof the first type of abrasive particle, suitable to facilitateprocessing. For example, the first particle film layer can have anaverage thickness of not greater than about 50% of the first averageparticle size. In other embodiments, the average thickness of the firstparticle film layer relative to the first average particle size can beless, such as not greater than about 45%, not greater than about 40%,not greater than about 35%, not greater than about 30%, not greater thanabout 25%, not greater than about 20%, not greater than about 15%, notgreater than about 10%, or even not greater than about 5%. Still, in atleast one non-limiting embodiment, the average thickness of the firstparticle film layer relative to the first average particle size can beat least about 1%, at least about 5%, at least about 10%, at least about15%, at least about 20%, at least about 25%, at least about 30%, atleast about 40%, or even at least about 45%. It will be appreciated thatthe average thickness of the first particle film layer relative to thefirst average particle size can be within a range between any of theminimum and maximum percentages noted above.

According to another embodiment, the second particle film layer can beformed to have a particular thickness relative to the first averageparticle size of the first type of abrasive particle, suitable tofacilitate processing. For example, the second particle film layer canhave an average thickness of not greater than about 50% of the firstaverage particle size. In other embodiments, the average thickness ofthe second particle film layer relative to the first average particlesize can be less, such as not greater than about 45%, not greater thanabout 40%, not greater than about 35%, not greater than about 30%, notgreater than about 25%, not greater than about 20%, not greater thanabout 15%, not greater than about 10%, or even not greater than about5%. Still, in at least one non-limiting embodiment, the averagethickness of the second particle film layer relative to the firstaverage particle size can be at least about 1%, at least about 5%, atleast about 10%, at least about 15%, at least about 20%, at least about25%, at least about 30%, at least about 40%, or even at least about 45%.It will be appreciated that the average thickness of the second particlefilm layer relative to the first average particle size can be within arange between any of the minimum and maximum percentages noted above.

It will further be appreciated that the second type of abrasive particlecan include a second particle coating layer. The second particle coatinglayer can include any of the features of the first particle coatinglayer, including properties, features, and characteristics relative tothe second type of abrasive particle.

After placing the abrasive particles (e.g., the first type of abrasiveparticles, the second type of abrasive particles, and any other types)on the first layer at step 104, the process can continue at step 105 bytreating the abrasive article to form fillets and make connectionbetween abrasive particles and the substrate. Treating may includeprocesses such as heating, curing, drying, melting, sintering,solidification and a combination thereof. In one particular embodiment,treating includes a thermal process, such as heating the first layer toa temperature sufficient to induce melting of the first layer, whileavoiding excessive temperatures to limit damage to the abrasiveparticles and substrate. For example, treating can include heating thesubstrate, first layer, and abrasive particles to a temperature of notgreater than about 450° C. Notably, the process of treating can beconducted at a treating temperature that is less, such as not greaterthan about 375° C., not greater than about 350° C., not greater thanabout 300° C., or even not greater than about 250° C. In otherembodiments, the process of treating can include heating the first layerto a melting point of at least about 100° C., at least about 150° C., oreven at least about 175° C.

It will be appreciated that the heating process can facilitate meltingof materials within the first layer and additional layers comprising theflux material to bond the abrasive particles to the first layer and thesubstrate. The heating process can facilitate the formation of aparticular bond between the abrasive particle and the first layer.Notably, in the context of coated abrasive particles, a metallic bondingregion can be formed between the particle coating material (e.g., thefirst particle coating layer and second particle coating layer) of theabrasive particles and the first layer material. The metallic bondingregion can be characterized by diffusion bond region having aninterdiffusion between at least one chemical species of the first layerand at least one species of the particle coating layer overlying theabrasive particles, such that the metallic bonding region comprises amixture of chemical species from the two component layers.

After forming the first layer and applying the additional layers forfacilitate binding of the abrasive particles, the excess material of theadditional layers can be removed. For example, according to anembodiment, a cleaning process may be utilized to remove the excessadditional layers, such as residual flux material. According to oneembodiment, the cleaning process may utilize one or a combination ofwater, acids, bases, surfactants, catalysts, solvents, and a combinationthereof. In one particular embodiment, the cleaning process can be astaged process, starting with a rinse of the abrasive article using agenerally neutral material, such as water or deionized water. The watermay be room temperature or hot, having a temperature of at least about40° C. After the rinsing operation the cleaning process may include analkaline treatment, wherein the abrasive article is traversed through abath having a particular alkalinity, which may include an alkalinematerial. The alkaline treatment may be conducted at room temperature,or alternatively, at elevated temperatures. For example, the bath of thealkaline treatment may have a temperature of at least about 40° C., suchat least about 50° C., or even at least about 70° C., and not greaterthan about 200° C. The abrasive article may be rinsed after the alkalinetreatment.

After the alkaline treatment, the abrasive article may undergo anactivation treatment. The activation treatment may include traversingthe abrasive article through a bath having a particular element orcompound, including an acid, a catalyst, a solvent, a surfactant, and acombination thereof. In one particular embodiment, the activationtreatment can include an acid, such as a strong acid, and moreparticularly hydrochloric acid, sulfuric acid, and a combinationthereof. In some instances, the activation treatment can include acatalyst that may include a halide or halide-containing material. Somesuitable examples of catalysts can include potassium hydrogen fluoride,ammonium bifluoride, sodium bifluoride, and the like.

The activation treatment may be conducted at room temperature, oralternatively, at elevated temperatures. For example, the bath of theactivation treatment may have a temperature of at least about 40° C.,but not greater than about 200° C. The abrasive article may be rinsedafter the activation treatment.

According to one embodiment, after suitably cleaning the abrasivearticle, an optional process may be utilized to facilitate the formationof abrasive particles having exposed surfaces after complete formationof the abrasive article. For example, in one embodiment, an optionalprocess of selectively removing at least a portion of the particlecoating layer on the abrasive particles may be utilized. The selectiveremoval process may be conducted such that the material of the particlecoating layer is removed while other materials of the abrasive article,including for example, the first layer are less affected, or evenessentially unaffected. According to a particular embodiment, theprocess of selectively removing comprises etching. Some suitable etchingprocesses can include wet etching, dry etching, and a combinationthereof. In certain instances, a particular etchant may be used that isconfigured to selectively remove the material of the particle coatinglayer of the abrasive particles and leaving the first layer intact. Somesuitable etchants can include nitric acid, sulfuric acid, hydrochlorideacid, organic acid, nitric salt, sulfuric salt, chloride salt, alkalinecyanide based solutions, and a combination thereof.

As described herein, the abrasive article can include a first type ofabrasive particle and a second type of abrasive particle different thanthe first type of abrasive particle. In certain instances, the selectiveremoval process can be conducted on only the first type of abrasiveparticle, only the second type of abrasive particle, or both the firsttype of abrasive particle and the second type of abrasive particle.Selective removal of the particle coating layer of either the first typeor second type may be facilitated by the use of a first type of abrasiveparticle having a first particle coating layer different than the secondparticle coating layer of the second type of abrasive particle.

In yet another embodiment, the formation of abrasive particles havingexposed surfaces (See, for example, FIGS. 12A and 12B) can befacilitated by the use of abrasive particles having a particle coatinglayer that is discontinuous. That is, the particle coating layer canoverlie a fraction of the total exterior surface area, such that theparticle coating layer has gaps or openings in the coating layer. Suchparticles may also facilitate the formation of abrasive particles havingexposed surfaces without the necessarily utilizing a selective removalprocess.

After treating the first layer at step 105, the process can continue atstep 106, by forming a bonding layer over the first layer and abrasiveparticles. Formation of the bonding layer can facilitate formation of anabrasive article having improved performance, including but not limitedto, wear resistance and particle retention. Furthermore, the bondinglayer can enhance abrasive particle retention for the abrasive article.In accordance with an embodiment, the process of forming the bondinglayer can include deposition of the bonding layer on the externalsurface of the article defined by the abrasive particles and the firstlayer. In fact, the bonding layer can be bonded directly to the abrasiveparticles and the first layer.

Forming the bonding layer can include a deposition process. Somesuitable deposition processes can include plating (electrolyte orelectroless), spraying, dipping, printing, coating, and a combinationthereof. In accordance with one particular embodiment, the bonding layercan be formed by a plating process. For at least one particularembodiment, the plating process can be an electrolyte plating process.In another embodiment, the plating process can include an electrolessplating process.

The bonding layer can be formed such that it can directly contact atleast a portion of the first layer, a portion of the first type ofabrasive particle, a portion of the second type of abrasive particle,the particle coating layer on the first type of abrasive particle, theparticle coating layer on the second type of abrasive particle, and acombination thereof.

The bonding layer can overlie a majority of an external surface of thesubstrate and an external surface of the first type of abrasiveparticle. Moreover, in certain instances, the bonding layer can overliea majority of an external surface of the substrate and an externalsurface of the second type of abrasive particle. In certain embodiments,the bonding layer can be formed such that it overlies at least 90% ofthe exposed surfaces of the abrasive particles and first layer. In otherembodiments, the coverage of the bonding layer can be greater, such thatit overlies at least about 92%, at least about 95%, or even at leastabout 97% of the exposed surfaces of the abrasive particles and firstlayer. In one particular embodiment, the bonding layer can be formedsuch that it can overlie essentially all of the external surfaces of thefirst type of abrasive particle, the second type of abrasive particle,and the substrate, thus defining the exterior surface of the abrasivearticle.

Still, in an alternative embodiment, the bonding layer can beselectively placed, such that exposed regions can be formed on theabrasive article. Further description of a selectively formed bondinglayer with exposed surfaces of diamond are provided herein.

The bonding layer can be made of a particular material, such as anorganic material, inorganic material, and a combination thereof. Somesuitable organic materials can include polymers such as a UV curablepolymer, thermosets, thermoplastics, and a combination thereof. Someother suitable polymer materials can include urethanes, epoxies,polyimides, polyamides, acrylates, polyvinyls, and a combinationthereof.

Suitable inorganic materials for use in the bonding layer can includemetals, metal alloys, cements, ceramics, composites, and a combinationthereof. In one particular instance, the bonding layer can be formed ofa material having at least one transition metal element, and moreparticularly a metal alloy containing a transition metal element. Somesuitable transition metal elements for use in the bonding layer caninclude lead, silver, copper, zinc, tin, titanium, molybdenum, chromium,iron, manganese, cobalt, niobium, tantalum, tungsten, palladium,platinum, gold, ruthenium, and a combination thereof. In certaininstances, the bonding layer can include nickel, and may be a metalalloy comprising nickel, or even a nickel-based alloy. In still otherembodiments, the bonding layer can consist essentially of nickel.

In accordance with one embodiment, the bonding layer can be made of amaterial, including for example, composite materials, having a hardnessthat is greater than a hardness of the first layer. For example, thebonding layer can have a Vickers hardness that is at least about 5%harder than a Vickers hardness of the first layer based on the absolutevalues of the equation ((Hb−Ht)/Hb)×100%, wherein Hb represents thehardness of the bonding layer and Ht represents the hardness of thefirst layer. In one embodiment, the bonding layer can be at least about10% harder, such as at least about 20% harder, at least about 30%harder, at least about 40% harder, at least about 50% harder, at leastabout 75% harder, at least about 90% harder, or even at least about 99%harder than the hardness of the first layer. Yet, in anothernon-limiting embodiment, the bonding layer may be not greater than about99% harder, such as not greater than about 90% harder, not greater thanabout 80% harder, not greater than about 70% harder, not greater thanabout 60% harder, not greater than about 50% harder, not greater thanabout 40% harder, not greater than about 30% harder, not greater thanabout 20% harder, not greater than about 10% harder than the hardness ofthe first layer. It will be appreciated that the difference between thehardness of the bonding layer and the first layer can be within a rangebetween any of the above minimum and maximum percentages.

Additionally, the bonding layer can have a fracture toughness (K1c) asmeasured by indentation method, that is at least about 5% greater thanan average fracture toughness of the first layer based on the absolutevalues of the equation ((Tb−Tt)/Tb)×100%, wherein Tb represents thefracture toughness of the bonding layer and Tt represents the fracturetoughness of the first layer. In one embodiment, the bonding layer canhave a fracture toughness of at least about 8% greater, such as at leastabout 10% greater, at least about 15% greater, at least about 20%greater, at least about 25% greater, at least about 30% greater, or evenat least about 40% greater than the fracture toughness of the firstlayer. Yet, in another non-limiting embodiment, the fracture toughnessof the bonding layer may be not greater than about 90% greater, such asnot greater than about 80% greater, not greater than about 70% greater,not greater than about 60% greater, not greater than about 50% greater,not greater than about 40% greater, not greater than about 30% greater,not greater than about 20% greater, or even not greater than about 10%greater than the fracture toughness of the first layer. It will beappreciated that the difference between the fracture toughness of thebonding layer and the fracture toughness of the first layer can bewithin a range between any of the above minimum and maximum percentages.

Optionally, the bonding layer can include a filler material. The fillercan be various materials suitable for enhancing performance propertiesof the finally-formed abrasive article. Some suitable filler materialscan include abrasive particles, pore-formers such as hollow sphere,glass spheres, bubble alumina, natural materials such as shells and/orfibers, metal particles, and a combination thereof.

In one particular embodiment, the bonding layer can include a filler inthe form of abrasive particles that may represent a third type ofabrasive particle, which can be the same as or different from the firsttype of abrasive particle and the second type of abrasive particle. Theabrasive particle filler can be significantly different than the firsttype and second type of abrasive particles, particularly with regard tosize, such that in certain instances the abrasive particle filler canhave an average particle size that is substantially less than theaverage particle size of the first type and second type of abrasiveparticles bonded to the first layer. For example, the abrasive particlefiller can have an average grain size that is at least about 2 timesless than the average particle size of the abrasive particles. In fact,the abrasive filler may have an average particle size that is evensmaller, such as on the order of at least 3 times less, such as at leastabout 5 times less, at least about 10 times less, and particularlywithin a range between about 2 times and about 10 times less than theaverage particle size of the first type of abrasive particle, secondtype of abrasive particle, or both.

The abrasive grain filler within the bonding layer can be made from amaterial such as carbides, carbon-based materials (e.g. fullerenes),diamond, borides, nitrides, oxides, oxynitrides, oxyborides, and acombination thereof. In particular instances, the abrasive grain fillercan be a superabrasive material such as diamond, cubic boron nitride, ora combination thereof.

After forming the bonding layer at step 106, the process may optionallycontinue at step 107, with forming a coating layer overlying the bondinglayer. In particular, the coating layer may be overlying the substrate,overlying the optional barrier layer, overlying the tacking film,overlying at least a portion of the abrasive particles (e.g., first typeand/or second type of abrasive particles), and overlying at least aportion of the bonding layer, and a combination thereof. In at least oneinstance, the coating layer can be formed such that it is in directcontact with at least a portion of the bonding layer, at least a portionof the abrasive particles (e.g., first type and/or second type ofabrasive particles), and a combination thereof.

Forming of the coating layer can include a deposition process. Somesuitable deposition processes can include plating (electrolyte orelectroless), spraying, dipping, printing, coating, and a combinationthereof. In accordance with one particular embodiment, the coating layercan be formed by a plating process, and more particularly, can beelectroplated directly to an external surface of the first type ofabrasive particle and the second type of abrasive particle. In anotherembodiment, the coating layer can be formed via a dip coating process.According to yet another embodiment, the coating layer can be formed viaspraying process.

The coating layer can overlie a portion of an exterior surface area ofthe bonding layer, abrasive particles, and a combination thereof. Forexample, the coating layer can overlie at least about 25% of an exteriorsurface area of the abrasive particle and the bonding layer. In stillanother design herein, the bonding layer can overlie a majority of anexternal surface of the bonding layer. Moreover, in certain instances,the coating layer can overlie a majority of an external surface of thebonding layer and abrasive particles. In certain embodiments, thecoating layer can be formed such that it overlies at least 90% of theexposed surfaces of the abrasive particles and bonding layer. In otherembodiments, the coverage of the coating layer can be greater, such thatit overlies at least about 92%, at least about 95%, or even at leastabout 97% of the exposed surfaces of the abrasive particles and bondinglayer. In one particular embodiment, the coating layer can be formedsuch that it can overlie essentially all of the external surfaces of thefirst type of abrasive particle, the second type of abrasive particle,and the bonding layer, thus defining the exterior surface of theabrasive article.

The coating layer can include an organic material, an inorganicmaterial, and a combination thereof. According to one aspect, thecoating layer can include a material such as a metal, metal alloy,cermet, ceramic, organic, glass, and a combination thereof. Moreparticularly, the coating layer can include a transition metal element,including for example, a metal from the group of titanium, vanadium,chromium, molybdenum, iron, cobalt, nickel, copper, silver, zinc,manganese, tantalum, tungsten, and a combination thereof. For certainembodiments, the coating layer can include a majority content of nickel,and in fact, may consist essentially of nickel. Alternatively, thecoating layer can include a thermoset, a thermoplastic, and acombination thereof. In one instance, the coating layer includes a resinmaterial and may be essentially free of a solvent.

In one particular embodiment, the coating layer can include a fillermaterial, which may be a particulate material. For certain embodiments,the coating layer filler material can be in the form of abrasiveparticles, which may represent a third type of abrasive particle thatcan be the same as or different from the first type of abrasive particleand the second type of abrasive particle. Certain suitable types ofabrasive particles for use as the coating layer filler material caninclude carbides, carbon-based materials (e.g., diamond), borides,nitrides, oxides, and a combination thereof. Some alternative fillermaterials can include pore-formers such as hollow sphere, glass spheres,bubble alumina, natural materials such as shells and/or fibers, metalparticles, and a combination thereof.

The coating filler material be significantly different than the firsttype and second type of abrasive particles, particularly with regard tosize, such that in certain instances the abrasive particle fillermaterial can have an average particle size that is substantially lessthan the average particle size of the first type and second type ofabrasive particles bonded to the first layer. For example, the coatinglayer filler material can have an average particle size that is at leastabout 2 times less than the average particle size of the abrasiveparticles. In fact, the coating layer filler material may have anaverage particle size that is even smaller, such as on the order of atleast 3 times less, such as at least about 5 times less, at least about10 times less, and particularly within a range between about 2 times andabout 10 times less than the average particle size of the first type ofabrasive particle, second type of abrasive particle, or both.

FIG. 2A includes a cross-sectional illustration of a portion of anabrasive article in accordance with an embodiment. FIG. 2B includes across-sectional illustration of a portion of an abrasive articleincluding an optional barrier layer in accordance with an embodiment. Asillustrated, the abrasive article 200 can include a substrate 201, whichis in the form of an elongated body, such as a wire. As furtherillustrated, the abrasive article can include a first layer 202 disposedover the entire external surface of the substrate 201. Furthermore, theabrasive article 200 can include abrasive particles 203 including acoating layer 204 overlying the abrasive particles 203. The abrasiveparticles 203 can be bonded to the first layer 202. In particular, theabrasive particles 203 can be bonded to the first layer 202 at theinterface 206, wherein a metallic bonding region can be formed asdescribed herein.

The abrasive article 200 can include a particle coating layer 204overlying the external surfaces of the abrasive particles 203. Notably,the coating layer 204 can be in direct contact with the first layer 202.As described herein, the abrasive particles 203, and more particularly,the particle coating layer 204 of the abrasive particles 203, can form ametallic bonding region at the interface between the coating layer 204and the first layer 202.

According to one embodiment, the first layer 202 can have a particularaverage thickness as compared to the average particle size of theabrasive particles 203. It will be appreciated that reference herein toan average particle size can include reference to the first averageparticle size of the first type of abrasive particle, the second averageparticle size of the second type of abrasive particle, or a totalaverage particle size, which is an average of the first average particlesize and the second average particle size. Furthermore, to the extentthat the abrasive article includes a third type of abrasive particle,the foregoing also applies.

The first layer 202 can have an average thickness that is not greaterthan about 80% of the average particle size of the abrasive particles203 (i.e., the first average particle size of the first type of abrasiveparticles, the second average particle size of the second type ofabrasive particles, or the total average particle size). The relativeaverage thickness of the first layer to the average particle size can becalculated by the absolute value of the equation ((Tp−Tt)/Tp)×100%,wherein Tp represents the average particle size and Tt represents theaverage thickness of the bonding layer. In other abrasive articles, thefirst layer 202 can have an average thickness of not greater than about70%, such as not greater than about 60%, not greater than about 50%, notgreater than about 40%, not greater than about 30%, not greater thanabout 25%, or even not greater than about 20% of the average particlesize of the abrasive particles 203. Still, in certain instances theaverage thickness of the first layer 202 can be at least about 2%, suchas at least about 3%, such as at least about 5%, at least about 8%, atleast about 10%, at least about 11%, at least about 12%, or even atleast about 13% of the average particle size of the abrasive particles203. It will be appreciated that the first layer 202 can have an averagethickness within a range between any of the minimum and maximumpercentages noted above.

In alternative terms, according to certain abrasive articles, the firstlayer 202 can have an average thickness that is not greater than about25 microns. In still other embodiments, the first layer 202 can have anaverage thickness that is not greater than about 20 microns, such as notgreater than about 10 microns, not greater than about 8 microns, or evennot greater than about 5 microns. In accordance with an embodiment, thefirst layer 202 can have an average thickness that is at least about 0.1microns, such as at least about 0.2 microns, at least about 0.5 micron,or even at least about 1 micron. It will be appreciated that the firstlayer 202 can have an average thickness within a range between any ofthe minimum and maximum values noted above.

In particular instances, for nickel coated abrasive particles having anaverage particle size of less than about 20 microns, the averagethickness of the first layer can be at least about 0.5 micron. Further,the average thickness can be at least about 1.0 microns, or at leastabout 1.5 microns. The average thickness can be limited, however, suchas not greater than about 5.0 microns, not greater than about 4.5microns, not greater than 4.0 microns, not greater than 3.5 microns, ornot greater than 3.0 microns. For abrasive particles having an averageparticle size within a range of 10 and 20 microns, the first layer 202can have an average thickness within a range between and including anyof the minimum and maximum thickness values noted above.

Alternatively, for nickel coated abrasive particles having an averageparticle size of at least about 20 microns, and more particularly withina range of about 40-60 microns, the average thickness of the first layercan be at least about 1 micron. Further, the average thickness can be atleast about 1.25 microns, at least about 1.5 microns, at least about1.75 microns, at least about 2.0 microns, at least about 2.25 microns,at least about 2.5 microns, or at least about 3.0 microns. The averagethickness can be limited, however, such as not greater than about 8.0microns, not greater than about 7.5 microns, not greater than 7.0microns, not greater than 6.5 microns, not greater than 6.0 microns, notgreater than 5.5 microns, not greater than 5.0 microns, not greater than4.5 microns, or not greater than 4.0 microns. For abrasive particleshaving an average particle size within a range of 40 and 60 microns, thefirst layer 202 can have an average thickness within a range between andincluding any of the minimum and maximum values noted above.

As further illustrated, the bonding layer 205 can be directly overlyingand directly bonded to the abrasive particles 203 and the first layer202. According to an embodiment, the bonding layer 205 can be formed tohave a particular thickness. For example, the bonding layer 205 can havean average thickness of at least about 5% of the average particle sizeof the abrasive particles 203 (i.e., the first average particle size ofthe first type of abrasive particles, the second average particle sizeof the second type of abrasive particles, or the total average particlesize). The relative average thickness of the bonding layer to theaverage particle size can be calculated by the absolute value of theequation ((Tp−Tb)/Tp)×100%, wherein Tp represents the average particlesize and Tb represents the average thickness of the bonding layer. Inother embodiments, the average thickness of the bonding layer 205 can begreater, such as at least about 10%, at least about 15%, at least about20%, at least about 30%, or even at least about 40%. Still, the averagethickness of the bonding layer 205 can be limited, such that it is notgreater than about 100%, not greater than about 90%, not greater thanabout 85%, or even not greater than about 80% of the average particlesize of the abrasive particles 203. It will be appreciated that thebonding layer 205 can have an average thickness within a range betweenany of the minimum and maximum percentages noted above.

In more particular instances, the bonding layer 205 can be formed tohave an average thickness that is at least 1 micron. For other abrasivearticles, the bonding layer 205 can have a greater average thickness,such as at least about 2 microns, at least about 3 microns, at leastabout 4 microns, at least about 5 microns, at least about 7 microns, oreven at least about 10 microns. Particular abrasive articles can have abonding layer 205 having an average thickness that is not greater thanabout 60 microns, such as not greater than about 50 microns, such as notgreater than about 40 microns, not greater than about 30 microns, or notgreater than about 20 microns. It will be appreciated that the bondinglayer 205 can have an average thickness within a range between any ofthe minimum and maximum values noted above.

The abrasive particles 203 can be positioned in a particular mannerrelative to other component layers of the abrasive article. For example,in at least one embodiment, a majority of the first type of abrasiveparticle can be spaced apart from the substrate. Moreover, in certaininstances, a majority of the first type of abrasive particle can bespaced apart from a barrier layer 230 of the substrate 201 (See, FIG. 2Bwhich includes an alternative illustration of a portion of an abrasivearticle according to an embodiment including a barrier layer). Moreparticularly, the abrasive article may be formed such that essentiallyall of the first type of abrasive particle is spaced apart from thebarrier layer. Additionally, it will be appreciated that a majority ofthe second type of abrasive particle can be spaced apart from thesubstrate 201 and the barrier layer 203. In fact, in certain instancesessentially all of the second type of abrasive particle is spaced apartfrom the barrier layer 203.

The abrasive article 250 illustrated in FIG. 2B includes an optionalbarrier layer, in accordance with an embodiment. As illustrated, thebarrier layer 230 can include an inner layer 231 in direct contact withthe substrate 201 and an outer layer 232 overlying the inner layer 231,and in particular, in direct contact with the inner layer 231.

FIG. 2C includes a cross-sectional illustration of a portion of anabrasive article including an optional coating layer in accordance withan embodiment. As illustrated, the abrasive article 260 can include acoating layer 235 overlying the bonding layer 205. According to aparticular embodiment, the coating layer 235 can have an averagethickness of at least about 5% of an average particle size of theabrasive particles 203 (i.e., the first average particle size of thefirst type of abrasive particles, the second average particle size ofthe second type of abrasive particles, or the total average particlesize). The relative average thickness of the coating layer to theaverage particle size can be calculated by the absolute value of theequation ((Tp−Tc)/Tp)×100%, wherein Tp represents the average particlesize and Tc represents the average thickness of the coating layer. Inother embodiments, the average thickness of the coating layer 235 can begreater, such as at least about 8%, at least about 10%, at least about15%, or even at least about 20%. Still, in another non-limitingembodiment, the average thickness of the coating layer 235 can belimited, such that it is not greater than about 50%, not greater thanabout 40%, not greater than about 30%, or even not greater than about20% of the average particle size of the abrasive particles 203. It willbe appreciated that the coating layer 235 can have an average thicknesswithin a range between any of the minimum and maximum percentages notedabove.

The coating layer 235 can have a particular average thickness relativeto the average thickness of the bonding layer 205. For example, theaverage thickness of the coating layer 235 can be less than an averagethickness of the bonding layer 205. In one particular embodiment, theaverage thickness of the coating layer 235 and the average thickness ofthe bonding layer can define a ratio (Tc:Tb) of at least about 1:2, atleast about 1:3, or even at least about 1:4. Still, in at least oneembodiment, the ratio can be not greater than about 1:20, such as notgreater than about 1:15, or even not greater than about 1:10. It will beappreciated that the ratio can be within a range between any of theupper and lower limits noted above.

According to a particular aspect, the coating layer 235 may be formed tohave an average thickness of not greater than about 15 microns, such asnot greater than about 10 microns, not greater than about 8 microns, oreven not greater than about 5 microns. Still, the average thickness ofthe coating layer 235 may be at least about 0.1 microns, such as atleast about 0.2 microns, or even at least about 0.5 microns. The coatinglayer may have an average thickness within a range between any of theminimum and maximum values noted above.

FIG. 2D includes a cross-sectional illustration of a portion of anabrasive article including a first type of abrasive particle and asecond type of abrasive particle in accordance with an embodiment. Asillustrated, the abrasive article 280 can include a first type ofabrasive particle 283 coupled to the substrate 201 and a second type ofabrasive particle 284 different than the first type of abrasive particle283 coupled to the substrate 201. The first type of abrasive particle283 can include any features described in embodiments herein, notablyincluding an agglomerated particle. The second type of abrasive particle284 can include any features described in embodiments herein, includingfor example, an unagglomerated particle. According to at least oneembodiment, the first type of abrasive particle 283 can be differentfrom the second type of abrasive particle 284 based on at least oneparticle characteristic of the group consisting of hardness, friability,toughness, particle shape, crystalline structure, average particle size,composition, particle coating, grit size distribution, and a combinationthereof.

Notably, the first type of abrasive particle 283 can be an agglomeratedparticle. FIG. 9 includes an illustration of an exemplary agglomeratedparticle according to an embodiment. The agglomerated particle 900 caninclude abrasive particles 901 contained within a binder material 903.Furthermore, as illustrated, the agglomerated particle can include acontent of porosity defined by pores 905. The pores may be presentwithin the binder material 903 between the abrasive particles 901, andin particular instances, essentially all of the porosity of theagglomerated particles can be present within the binder material 903.

According to one particular aspect, the abrasive article can be formedto have a particular abrasive particle concentration. For example, inone embodiment, the average particle size (i.e., the first averageparticle size or the second average particle size or the total averageparticle size) can be less than about 20 microns, and the abrasivearticle can have an abrasive particle concentration of at least about 5particles per mm of substrate. It will be appreciated that reference tothe particles per length is reference to the first type of abrasiveparticle, the second type of abrasive particle, or the total content ofall types of abrasive particles of the article. In yet anotherembodiment, the abrasive particle concentration can be at least about 20particles per mm of substrate, at least about 30 particles per mm ofsubstrate, at least about 60 particles per mm of substrate, at leastabout 100 particles per mm of substrate, at least about 200 particlesper mm of substrate, at least about 250 particles per mm of substrate,or even at least about 300 particles per mm of substrate. In anotheraspect, the abrasive particle concentration may be no greater than about800 particles per mm of substrate, such as no greater than about 700particles per mm of substrate, no greater than about 650 particles permm of substrate, or no greater than about 600 particles per mm ofsubstrate. It will be appreciated that the abrasive particleconcentration can be within a range between any of these above minimumand maximum values.

According to one particular aspect, the abrasive article can be formedto have a particular abrasive particle concentration. For example, inone embodiment, the average particle size (i.e., the first averageparticle size or the second average particle size or the total averageparticle size) can be at least about 20 microns, and the abrasivearticle can have an abrasive particle concentration of at least about 10particles per mm of substrate, such as, at least about 7 particles permm of substrate or even at least about 5 particles per mm of substrate.It will be appreciated that reference to the particles per length isreference to the first type of abrasive particle, the second type ofabrasive particle, or the total content of all types of abrasiveparticles of the article. In yet another embodiment, the abrasiveparticle concentration can be at least about 20 particles per mm ofsubstrate, at least about 30 particles per mm of substrate, at leastabout 60 particles per mm of substrate, at least about 80 particles permm of substrate, or even at least about 100 particles per mm ofsubstrate. In another aspect, the abrasive particle concentration may beno greater than about 200 particles per mm of substrate, such as nogreater than about 175 particles per mm of substrate, no greater thanabout 150 particles per mm of substrate, or no greater than about 100particles per mm of substrate. It will be appreciated that the abrasiveparticle concentration can be within a range between any of these aboveminimum and maximum values.

In another aspect, the abrasive article can be formed to have aparticular abrasive particle concentration, measured as carats perkilometer length of the substrate. For example, in one embodiment, theaverage particle size (i.e., the first average particle size or thesecond average particle size or the total average particle size) can beless than about 20 microns, and the abrasive article can have anabrasive particle concentration of at least about 0.5 carats perkilometer of the substrate. It will be appreciated that reference to theparticles per length is reference to the first type of abrasiveparticle, the second type of abrasive particle, or the total content ofall types of abrasive particles of the article. In another embodiment,the abrasive particle concentration can be at least about 1.0 carats perkilometer of substrate, such as at least about 1.5 carats per kilometerof substrate, at least about 2.0 carats per kilometer of substrate, atleast about 3.0 carats per kilometer of substrate, at least about 4.0carats per kilometer of substrate, or even at least about 5.0 carats perkilometer of substrate. Still, in one non-limiting embodiment, theabrasive particle concentration may be not be greater than 15.0 caratsper kilometer of substrate, not greater than 14.0 carats per kilometerof substrate, not greater than 13.0 carats per kilometer of substrate,not greater than 12.0 carats per kilometer of substrate, not greaterthan 11.0 carats per kilometer of substrate, or even not greater than10.0 carats per kilometer of substrate. The abrasive particleconcentration can be within a range between any of the above minimum andmaximum values.

For yet another aspect, the abrasive article can be formed to have aparticular abrasive particle concentration, wherein the average particlesize (i.e., the first average particle size or the second averageparticle size or the total average particle size) can be at least about20 microns. In such instances, the abrasive article can have an abrasiveparticle concentration of at least about 0.5 carats per kilometer of thesubstrate. It will be appreciated that reference to the particles perlength is reference to the first type of abrasive particle, the secondtype of abrasive particle, or the total content of all types of abrasiveparticles of the article. In another embodiment, the abrasive particleconcentration can be at least about 3 carats per kilometer of substrate,such as at least about 5 carats per kilometer of substrate, at leastabout 10 carats per kilometer of substrate, at least about 15 carats perkilometer of substrate, at least about 20 carats per kilometer ofsubstrate, or even at least about 50 carats per kilometer of substrate.Still, in one non-limiting embodiment, the abrasive particleconcentration may be not be greater than 200 carats per kilometer ofsubstrate, not greater than 150 carats per kilometer of substrate, notgreater than 125 carats per kilometer of substrate, or even not greaterthan 100 carats per kilometer of substrate. The abrasive particleconcentration can be within a range between any of the above minimum andmaximum values.

FIG. 10A includes a longitudinal side illustration of a portion of anabrasive article according to an embodiment. FIG. 10B includes across-sectional illustration of a portion of the abrasive article ofFIG. 10A according to an embodiment. In particular, the abrasive article1000 can include a first type of abrasive particle 283 that can define afirst layer of abrasive particles 1001. As illustrated, and according toan embodiment, the first layer of abrasive particles 1001 can define afirst pattern 1003 on the surface of the article 1000. The first pattern1003 can be defined by a relative arrangement of at least a portion(e.g., a group) of the first type of abrasive particle 283 relative toeach other. The arrangement or ordered array of the group of first typeof abrasive particles may be described relative to at least onedimensional component of the substrate 201. Dimensional components caninclude a radial component, wherein a group of the first type ofabrasive particle 283 can be arranged in an ordered array relative to aradial dimension 1081 that can define a radius or diameter (or thicknessif not circular) of the substrate 201. Another dimensional component caninclude an axial component, wherein a group of the first type ofabrasive particle 283 can be arranged in an ordered array relative to alongitudinal dimension 1080 that can define a length (or thickness ifnot circular) of the substrate 201. Yet another dimensional componentcan include a circumferential component, wherein a group of the firsttype of abrasive particle 283 can be arranged in an ordered arrayrelative to a circumferential dimension 1082 that can define acircumference (or periphery if not circular) of the substrate 201.

According to at least one embodiment, the first pattern 1003 can bedefined by a repeating axial component. As illustrated in FIG. 10A, thefirst pattern 1003 includes an ordered array of a group of the firsttype of abrasive particle 283 overlying the surface of the substrate 201that defines a repeating axial component, wherein each of the first typeof abrasive particle 283 within the group can have an ordered andpredetermined axial position relative to each other. Statedalternatively, each of the first type of abrasive particle within thegroup defining the first pattern 1003 are longitudinally spaced apartfrom each other in an ordered manner thus defining a repeating axialcomponent of the first pattern 1003. While the foregoing has describedthe first pattern 1003 as defined by a group of the first type ofabrasive particle, it will be appreciated that a pattern can be definedby a combination of different types of abrasive particles, such as anordered array of the first and second types of abrasive particles.

As further illustrated in FIG. 10A, the abrasive article 1000 caninclude a second type of abrasive particle 284 that can define a secondlayer of abrasive particles 1002. The second layer of abrasive particles1002 can be different than the first layer of abrasive particles 1001.In particular designs, the first layer of abrasive particles 1001 candefine a first radial position on the substrate 201 and the second layerof abrasive particles 1002 can define a second radial position on thesubstrate 201 that is different than the first radial position of thefirst layer of abrasive particles 1001. Moreover, according to oneembodiment, the first radial position of the first layer of abrasiveparticles 1001 and the second radial position defined by the secondlayer of abrasive particles 1002 can be radially spaced apart from eachother relative to the radial dimension 1081.

In yet another embodiment, the first layer of abrasive particles 1001can define a first axial position and the second layer of abrasiveparticles 1002 can define a second axial position spaced apart from thefirst axial position relative to the longitudinal dimension 1080.According to another embodiment, the first layer of abrasive particles1001 can define a first circumferential position and the second layer ofabrasive particles 1002 can define a second circumferential positionspaced apart from the first circumferential position relative to thecircumferential dimension 1082.

In at least one embodiment, the abrasive article 1000 can include afirst type of abrasive particle 283 that can define a first layer ofabrasive particles 1001, wherein each of the first type of abrasiveparticle 283 are substantially uniformly dispersed relative to eachother on the surface of the abrasive article. Furthermore, asillustrated, the abrasive article 1000 can include a second type ofabrasive particle 284 that can define a second layer of abrasiveparticles 100, wherein each abrasive particle of the second type ofabrasive particle 284 is substantially uniformly dispersed relative tothe other abrasive particles on the surface of the abrasive article.

As illustrated, and according to an embodiment, the first layer ofabrasive particles 1001 can be associated with a first pattern 1003 onthe surface of the article 1000 and the second layer of abrasiveparticles 1002 can be associated with a second pattern 1004 on thesurface of the article 1000. Notably, in at least one embodiment, thefirst pattern 1002 and the second pattern 1004 are different relative toeach other. According to one embodiment, the first pattern 1002 andsecond pattern 1004 can be separated from each other by a channel 1009.Moreover, depending upon the method of forming, the first pattern 1002may be associated with a first pattern of a first layer materialrelative to the surface of the substrate 201 (not shown) or a firstpattern of the bonding layer material relative to the surface of thesubstrate 201 (not shown). Additionally or alternatively, the secondpattern 1004 can be associated with a second pattern of a first layermaterial relative to the surface of the substrate 201 (not shown). Thesecond pattern of the first layer may be different than the firstpattern of the first layer. Still, in certain instances, the secondpattern of the first layer can be the same as the first pattern of thefirst layer. According to one embodiment, the second pattern 1004 can beassociated with a second pattern of the bonding layer relative to thesurface of the substrate 201 (not shown), which may be different thanthe first pattern of the bonding layer. Still, in at least oneembodiment, the second pattern of the bonding layer may be the same asthe first pattern of the bonding layer. The first pattern of the firstlayer can be different than the second pattern of the first layer by atleast a radial component, an axial component, a circumferentialcomponent, and a combination thereof. Moreover, the first pattern of thebonding layer can be different than the second pattern of the bondinglayer by at least a radial component, an axial component, acircumferential component, and a combination thereof.

As illustrated in FIG. 10A, the first pattern 1003 can be defined by atwo-dimensional shape, such as a polygonal two-dimensional shape, suchas a rectangle. Likewise, the second pattern 1004 can be defined by atwo-dimensional shape, such as a polygonal two-dimensional shape, suchas a rectangle. It will be appreciated that other two-dimensional shapesmay be employed.

According to one particular embodiment, the second pattern 1004 caninclude an ordered array of a group of the second type of abrasiveparticle 284 overlying the surface of the substrate 201 that defines arepeating axial component, wherein each of the second type of abrasiveparticle 284 within the group can have an ordered and predeterminedaxial position relative to each other. For example, each of the secondtype of abrasive particle 284 within the group defining the secondpattern 1004 can be longitudinally spaced apart from each other in anordered manner thus defining a repeating axial component of the secondpattern 1004. While the foregoing has described the second pattern 1004as defined by a group of the second type of abrasive particle, it willbe appreciated that any pattern herein can be defined by a combinationof different types of abrasive particles, such as an ordered array ofthe first and second types of abrasive particles.

As further illustrated in FIG. 10A, the abrasive article 1000 can have athird pattern 1005 that can include an ordered array of a group of thefirst type of abrasive particle 283 and the second type of abrasiveparticle 284 overlying the surface of the substrate 201 that defines arepeating radial component. Each of the first type of abrasive particle283 and second type of abrasive particle 284 within the group can havean ordered and predetermined radial position relative to each other.That is, for example, each of the first type of abrasive particle 283and second type of abrasive particle 284 within the group defining thethird pattern 1005 are radially spaced apart from each other in anordered manner thus defining a repeating radial component of the thirdpattern 1005.

In addition to the repeating radial component, the third pattern 1005can include an ordered array of a group of the first type of abrasiveparticle 283 and the second type of abrasive particle 284 overlying thesurface of the substrate 201 that defines a repeating circumferentialcomponent. As illustrated in FIGS. 10A and 10B, the third pattern 1005can be defined by each of the first type of abrasive particle 283 andsecond type of abrasive particle 284 within the group having an orderedand predetermined circumferential position relative to each other. Thatis, for example, each of the first type of abrasive particle 283 andsecond type of abrasive particle 284 within the group defining the thirdpattern 1005 are circumferentially spaced apart from each other in anordered manner thus defining a repeating circumferential component ofthe third pattern 1005.

FIG. 10C includes a longitudinal side illustration of a portion of anabrasive article according to an embodiment. In particular, the abrasivearticle 1020 can include a first type of abrasive particle 283 that candefine a first layer of abrasive particles 1021. Notably, the firstlayer of abrasive particles 1021 can be arranged relative to each otherto have a repeating axial component, repeating radial component, andrepeating circumferential component. In accordance with one particularembodiment, the first layer of abrasive particles 1021 can define afirst helical path extending around the substrate 201 and defined by aplurality of turns that can be axially spaced apart from each other.According to one embodiment, a single turn includes an extension of thefirst layer of abrasive particles 1021 around the circumference of thearticle for 360 degrees. The first helical path may be continuous, oralternatively, may be defined by an axial gap, a radial gap, acircumferential gap, and a combination thereof.

Moreover, the abrasive article 1020 can include a second type ofabrasive particle 284 that can define a second layer of abrasiveparticles 1022. Notably, the second layer of abrasive particles 1022 canbe arranged relative to each other to have a repeating axial component,repeating radial component, and repeating circumferential component. Inaccordance with one particular embodiment, the second layer of abrasiveparticles 1022 can define a second helical path extending around thesubstrate 201. The second helical path can be defined by a plurality ofturns, wherein the turns can be axially spaced apart from each other,and wherein a single turn includes an extension of the second layer ofabrasive particles 1022 around the circumference of the article for 360degrees. The second helical path may be continuous, or alternatively,may be interrupted, wherein the second helical path can have an axialgap, a radial gap, a circumferential gap, and a combination thereof.

As illustrated, and according to a particular embodiment, the firstlayer of abrasive particles 1021 and second layer of abrasive particles1022 can define an intertwined helical path, wherein the first layer ofabrasive particles 1021 and second layer of abrasive particles 1022alternate in the longitudinal dimension 1080. It will be appreciatedthat a single helical path can be defined by a combination of the firsttype of abrasive particle and the second type of abrasive particle.

According to a particular embodiment, a lubricious material may beincorporated into the abrasive article to facilitate improvedperformance. FIGS. 11A-11B include illustrations of various abrasivearticles having different deployments of a lubricious material accordingto embodiments herein. In at least one embodiment, the abrasive articlecan include a lubricious material overlying the substrate. In anotherinstance, the lubricious material can be overlying the first layer.Alternatively, the lubricious material may be in direct contact with thefirst layer, and more particularly, may be contained within the firstlayer. For one design of an embodiment, the lubricious material can beoverlying the abrasive particles, and even may be in direct contact withthe abrasive particles. In still another embodiment, the lubriciousmaterial can be overlying the bonding layer, may be at the bondinglayer, and in more particular instance, in direct contact with thebonding layer. According to one embodiment, the lubricious material canbe contained within the bonding layer. Yet, in one alternativeembodiment, the lubricious material can be overlying a coating layer,and more particularly, can be in direct contact with the coating layer,and even more particularly, can be contained within the coating layer.The lubricious material may be formed on the exterior of the abrasivearticle, such that it is configured to make contact with a workpiece.

The lubricious material may define at least a portion of the exteriorsurface of the abrasive article. Notably, the lubricious material can bein the form of a continuous coating, such as the lubricious material1103 illustrated in FIG. 11A of the abrasive article 1100. In suchinstances, the lubricious material can overlie a majority of the surfaceof the abrasive article 1100 and define a majority of the exteriorsurface of the abrasive article 1100. According to one design of anembodiment, the lubricious material can define essentially the entireexterior surface of the abrasive article 1100.

According to another embodiment, the lubricious material may define anon-continuous layer, wherein the lubricious material overlies thesubstrate and defines a fraction of the exterior surface of the abrasivearticle. The non-continuous layer may be defined by a plurality of gapsextending between portions of the lubricious material, wherein the gapsdefine regions absent the lubricious material.

According to one embodiment, the lubricious material can be in the formof discrete particles comprising a lubricious material. The discreteparticles including the lubricious material may consist essentially ofthe lubricious material. More particularly, the discrete particles canbe disposed at various places within the abrasive article, including butnot limited to, in direct contact with the bonding layer, at leastpartially contained within the bonding layer, contained entirely withinthe bonding layer, at least partially contained within the coatinglayer, in direct contact with a coating layer and a combination thereof.For example, as illustrated in FIG. 11B, the lubricious material 1103 ispresent as discrete particles contained in the bonding layer 205.

For at least one embodiment, the lubricious material can be an organicmaterial, an inorganic material, a natural material, a syntheticmaterial, and a combination thereof. In one particular instance, thelubricious material can include a polymer, such as a fluoropolymer. Oneparticularly suitable polymer material can includepolytetrafluoroethylene (PTFE). In at least one embodiment, thelubricious material can consist essentially of PTFE.

Various methods of providing the lubricious material to the abrasivearticle may be utilized. For example, the process of providing thelubricious material may be conducted via a depositing process. Exemplarydeposition processes can include spraying, printing, plating, coating,gravity coating, dipping, die coating, electrostatic coating, and acombination thereof.

Additionally, the process of providing the lubricious material may beconducted at different times during processing. For example, providingthe lubricious material can be conducted simultaneously with forming thefirst layer. Alternatively, providing the lubricious material can beconducted simultaneously with providing the abrasive particles. In yetanother embodiment, providing the lubricious material can be completedsimultaneously with providing the bonding layer. Moreover, in oneoptional process, providing the lubricious material can be conductedsimultaneously with providing a coating layer overlying the bondinglayer.

Still, the process of providing the lubricious material can be conductedafter completing certain processes. For example, providing thelubricious material can be conducted after forming the first layer,after providing the abrasive particles, after providing the bondinglayer, or even after providing a coating layer.

Alternatively, it may be suitable to provide the lubricious materialprior to forming certain layers. For example, providing the lubriciousmaterial can be conducted before forming the first layer, beforeproviding the abrasive particles, before providing the bonding layer, oreven before providing a coating layer.

Certain articles according to embodiments herein can be processedaccording to a particular method to facilitate the formation of abrasiveparticles having an exposed surface. FIG. 12A includes an illustrationof an abrasive article including an abrasive particle having an exposedsurface. As illustrated in FIG. 12A, the abrasive article can be formedsuch that an abrasive particle 203 (e.g., first type or second type ofabrasive particle) can have an exposed surface 1201. According to anembodiment, the abrasive particle 203 can have a particle coating 1205overlying a surface of the abrasive particle 203, and preferentiallydisposed proximate to a lower surface 1204 of the abrasive particle 203.In particular, the particle coating layer 1205 can be a non-continuouscoating that is preferentially disposed at a lower surface 1204 of theabrasive particle 203 adjacent the substrate 201 and first layer 202.Notably, the particle coating layer 1205 may not necessarily extend overan upper surface 1203 of the abrasive particle 203, which is spaced at agreater distance from the substrate 201 than the lower surface 1204, andfacilitate the formation of the exposed surface 1201. The particlecoating layer 1205 may be removed from the upper surface 1203 of theabrasive particle via a selective removal process prior to forming thebonding layer as described in embodiments herein. The absence of a theparticle coating layer 1205 at the upper surface 1203 can facilitate theformation of an exposed surface 1201, since the bonding layer materialmay not necessarily wet the upper surface 1203 of the abrasive particle203 during forming.

According to one embodiment, the exposed surface 1201 can be essentiallyabsent a metal material. In particular, the exposed surface 1201 canconsist essentially of the abrasive particle 203 and have no overlyinglayers. In certain instances, the exposed surface 1201 can consistessentially of diamond.

FIG. 12B includes a picture of an abrasive article according to anembodiment including abrasive particles having exposed surfaces. Theexposed surfaces 1201 can exist for at least about 5% of an amount ofabrasive particles of the abrasive article. It will be appreciated thatthe amount of abrasive particles can be a total amount of only the firsttype of abrasive particles, a total amount of only the second type ofabrasive particles, or a total amount of all types of abrasive particlespresent in the abrasive article. In other instances, the content ofabrasive particles having an exposed surface can be at least about 10%,such as at least about 20%, at least about 30%, at least about 40%, atleast about 50%, at least about 60%, at least about 70%, at least about80%, or even at least about 90%. Still, in a non-limiting embodiment,not greater than about 99%, such as not greater than about 98%, notgreater than about 95%, not greater than about 80%, such as not greaterthan about 70%, not greater than about 60%, not greater than about 505,not greater than about 40%, not greater than about 30%, not greater thanabout 25%, or even not greater than about 20% of an amount of theabrasive particles have an exposed surface. It will be appreciated thatthe amount of abrasive particles having an exposed surface can be withina range between any of the above noted minimum and maximum percentages.

The bonding layer may have a particular contour at the exposed surface1201. As illustrated in FIG. 12B, the bonding layer 205 can have ascalloped edge 1205 at an interface between the bonding layer 205 and anexposed surface 1201 of the abrasive particles. The scalloped edge mayfacilitate improved material removal and improved abrasive particleretention.

Certain processing techniques can facilitate use of different types ofabrasive particles having different exposed surfaces. For example, theabrasive article can include a first type of abrasive particle and asecond type of abrasive particle, wherein essentially none of the totalcontent of the second type of abrasive particle has an exposed surfacewhile at least a portion of the total content of the first type ofabrasive particle has an exposed surface. Still, in other instances, atleast a portion of a total amount of the second type of abrasiveparticle can have an exposed surface. Moreover, in one particularembodiment, the amount of the second type of abrasive particle having anexposed surface is less than the amount of the first type of abrasiveparticle having an exposed surface. Alternatively, the amount of thesecond type of abrasive particle having an exposed surface is greaterthan the amount of the first type of abrasive particle having an exposedsurface. Yet, according to another embodiment, the total amount of thesecond type of abrasive particle having an exposed surface issubstantially the same as the amount of the first type of abrasiveparticle having an exposed surface.

The abrasive articles of the embodiments herein may be wire saws thatare particularly suited for slicing of workpieces. The workpieces can bevarious materials, including but not limited to, ceramic, semiconductivematerial, insulating material, glass, natural materials (e.g., stone),organic material, and a combination thereof. More particularly, theworkpieces can include oxides, carbides, nitrides, minerals, rocks,single crystalline materials, multicrystalline materials, and acombination thereof. For at least one embodiment, an abrasive article ofan embodiment herein may be suitable for slicing a workpiece ofsapphire, quartz, silicon carbide, and a combination thereof.

According to at least one aspect, the abrasive articles of theembodiments can be used on particular machines, and may be used atparticular operating conditions that have improved and unexpectedresults compared to conventional articles. While not wishing to be boundto a particular theory, it is thought there may be some synergisticeffect between the features of the embodiments.

Generally, cutting, slicing, bricking, squaring, or any other operationcan be conducted by moving the abrasive article (i.e., wire saw) and theworkpiece relative to each other. Various types and orientations of theabrasive articles relative to the workpieces may be utilized, such thata workpiece is sectioned into wafers, bricks, rectangular bars,prismatic sections, and the like.

This may be accomplished using a reel-to-reel machine, wherein movingcomprises reciprocating the wire saw between a first position and asecond position. In certain instances, moving the abrasive articlebetween a first position and a second position comprises moving theabrasive article back and forth along a linear pathway. While the wireis being reciprocated, the workpiece may also be moved, including forexample, rotating the workpiece. FIG. 15 includes an illustration of areel-to-reel machine using an abrasive article to slice a workpiece.

Alternatively, an oscillating machine may be utilized with any abrasivearticle according to the embodiments herein. Use of an oscillatingmachine can include moving the abrasive article relative to theworkpiece between a first position and second position. The workpiecemay be moved, such as rotated, and moreover the workpiece and wire canboth be moved at the same time relative each other. An oscillatingmachine may utilize a back and forth motion of the wire guide relativeto the workpiece, wherein a reel-to-reel machine does not necessarilyutilize such a motion. FIG. 16 includes an illustration of anoscillation machine using an abrasive article to slice a workpiece.

For some applications, during the slicing operation the process mayfurther include providing a coolant at an interface of the wire saw andworkpiece. Some suitable coolants include water-based materials,oil-based materials, synthetic materials, and a combination thereof.

In certain instances, slicing can be conducted as a variable rateoperation. The variable rate operation can include moving the wire andworkpiece relative to each other for a first cycle and moving the wireand workpiece relative to each other for a second cycle. Notably, thefirst cycle and the second cycle may be the same or different. Forexample, the first cycle can include translation of the abrasive articlefrom a first position to a second position, which in particular, mayinclude translation of the abrasive article through a forward andreverse direction cycle. The second cycle can include translation of theabrasive article from a third position to a fourth position, which mayalso include translation of the abrasive article through a forward andreverse direction cycle. The first position of the first cycle can bethe same as the third position of the second cycle, or alternatively,the first position and the third position may be different. The secondposition of the first cycle can be the same as the fourth position ofthe second cycle, or alternatively, the second position and the fourthposition may be different.

According to a particular embodiment, the use of an abrasive article ofan embodiment herein in a variable rate cycle operation can include afirst cycle that includes the elapsed time to translate the abrasivearticle from a starting position in a first direction (e.g., forward) toa temporary position, and in a second direction (e.g., backward) fromthe temporary position, thus returning to the same starting position orclose to the starting position. Such a cycle can include the durationfor accelerating the wire from 0 m/s to set wire speed in the forwarddirection, the elapsed time for moving the wire at set wire speed in theforward direction, the elapsed time on decelerating the wire from setwire speed to 0 m/s in the forward direction, the elapsed time onaccelerating the wire from 0 m/s to set wire speed in the backwarddirection, the elapsed time on moving the wire at set wire speed in thebackward direction, and the elapsed time on decelerating the wire fromset wire speed to 0 m/s in the backward direction. FIG. 17 includes anexemplary plot of wire speed versus time for a single cycle of avariable rate cycle operation.

According to one particular embodiment, the first cycle can be at leastabout 30 seconds, such as at least about 60 seconds, or event leastabout 90 seconds. Still, in one non-limiting embodiment, the first cyclecan be not greater than about 10 minutes. It will be appreciated thatthe first cycle can have a duration within a range between any of theminimum and maximum values above.

In yet another embodiment, the second cycle can be at least about 30seconds, such as at least about 60 seconds, or even at least about 90seconds. Still, in one non-limiting embodiment, the second cycle can benot greater than about 10 minutes. It will be appreciated that thesecond cycle can have a duration within a range between any of theminimum and maximum values above.

The total number of cycles in a for a cutting process may vary, but canbe at least about 20 cycles, at least about 30 cycles, or even at leastabout 50 cycles. In particular instances, the number of cycles may benot greater than about 3000 cycles or not greater than about 2000cycles. The cutting operation may last for a duration of at least about1 hour or at least about 2 hours. Still, depending upon the operation,the cutting process may be longer, such as at least about 10 hours, oreven 20 hours of continuous cutting.

In certain cutting operations, the wire saw of any embodiment herein maybe particularly suited for operation at a particular feed rate. Forexample, the slicing operation can be conducted at a feed rate of atleast about 0.05 mm/min, at least about 0.1 mm/min, at least about 0.5mm/min, at least about 1 mm/min, or even at least about 2 mm/min Still,in one non-limiting embodiment, the feed rate may be not greater thanabout 20 mm/min. It will be appreciated that the feed rate can be withina range between any of the minimum and maximum values above.

For at least one cutting operation, the wire saw of any embodimentherein may be particularly suited for operation at a particular wiretension. For example, the slicing operation can be conducted at a wiretension of at least about 30% of a wire break load, such as at leastabout 50% of the wire break load, or even at least about 60% of a breakload. Still, in one non-limiting embodiment, the wire tension may be notgreater than about 98% of the break load. It will be appreciated thatthe wire tension can be within a range between any of the minimum andmaximum percentages above.

According to another cutting operation, the abrasive article can have aVWSR range that facilitates improved performance. VWSR is the variablewire speed ratio and can generally be described by the equationt2/(t1+t3), wherein t2 is the elapsed time when the abrasive wire movesforward or backward at a set wire speed, wherein t1 is the elapsed timewhen the abrasive wire moves forward or backward from 0 wire speed toset wire speed, and t3 is the elapsed time when the abrasive wire movesforward or backward from constant wire speed to 0 wire speed. See, forexample FIG. 17. For example, the VWSR range of a wire saw according toan embodiment herein can be at least about 1, at least about 2, at leastabout 4, or even at least about 8. Still, in one non-limitingembodiment, the VWSR rate may be not greater than about 75 or notgreater than about 20. It will be appreciated that the VWSR rate can bewithin a range between any of the minimum and maximum values above. Inone embodiment, an exemplary machine for variable wire speed ratiocutting operations can be a Meyer Burger DS265 DW Wire Saw machine.

Certain slicing operations may be conducted on workpieces includingsilicon, which can be single crystal silicon or multicrystallinesilicon. According to one embodiment, use of an abrasive articleaccording to an embodiment demonstrates a life of at least about 8m²/km, such as at least about 10 m²/km, at least about 12 m²/km, or evenat least about 15 m²/km. The wire life can be based upon the wafer areagenerated per kilometer of abrasive wire used, wherein wafer areagenerated is calculated based on one side of the wafer surface. In suchinstances, the abrasive article may have a particular abrasive particleconcentration, such as at least about 0.5 carats per kilometer of thesubstrate, at least about 1.0 carats per kilometer of substrate, atleast about 1.5 carats per kilometer of substrate, or even at leastabout 2.0 carats per kilometer of substrate. Still, the concentrationmay be not greater than about 20 carats per kilometer of substrate, oreven not greater than about 10 carats per kilometer of substrate. Theaverage particle size of the abrasive particles can be less than about20 microns. It will be appreciated that the abrasive particleconcentration can be within a range between any of the minimum andmaximum values above. The slicing operation may be conducted at a feedrate as disclosed herein.

According to another operation, a silicon workpiece including singlecrystal silicon or multicrystalline silicon can be sliced with anabrasive article according to one embodiment, and the abrasive articlecan have a life of at least about 0.5 m²/km, such as at least about 1m²/km, or even at least about 1.5 m²/km. In such instances, the abrasivearticle may have a particular abrasive particle concentration, such asat least about 5 carats per kilometer of the substrate, at least about10 carats per kilometer of substrate, of at least about 20 carats perkilometer of substrate, at least about 40 carats per kilometer ofsubstrate. Still, the concentration may be not greater than about 300carats per kilometer of substrate, or even not greater than about 150carats per kilometer of substrate. The average particle size of theabrasive particles can be less than about 20 microns. It will beappreciated that the abrasive particle concentration can be within arange between any of the minimum and maximum values above.

The slicing operation may be conducted at a feed rate of at least about1 mm/min, at least about 2 mm/min, at least about 3 mm/min, at leastabout 5 mm/min. Still, in one non-limiting embodiment, the feed rate maybe not greater than about 20 mm/min. It will be appreciated that thefeed rate can be within a range between any of the minimum and maximumvalues above.

According to another operation, a sapphire workpiece can be sliced usingan abrasive article of an embodiment herein. The sapphire workpiece mayinclude a c-plane sapphire, an a-plane sapphire, or a r-plane sapphirematerial. For at least one embodiment, the abrasive article can slicethrough the sapphire workpiece and exhibit a life of at least about 0.1m²/km, such as at least about 0.2 m²/km, at least about 0.3 m²/km, atleast about 0.4 m²/km, or even at least about 0.5 m²/km. In suchinstances, the abrasive article may have a particular abrasive particleconcentration, such as at least about 5 carats per kilometer of thesubstrate, at least about 10 carats per kilometer of substrate, of atleast about 20 carats per kilometer of substrate, at least about 40carats per kilometer of substrate. Still, the concentration may be notgreater than about 300 carats per kilometer of substrate, or even notgreater than about 150 carats per kilometer of substrate. The averageparticle size of the abrasive particles can be greater than about 20microns. It will be appreciated that the abrasive particle concentrationcan be within a range between any of the minimum and maximum valuesabove.

The foregoing slicing operation on the workpiece of sapphire may beconducted at a feed rate of at least about 0.05 mm/min, such as at leastabout 0.1 mm/min, or even at least about 0.15 mm/min. Still, in onenon-limiting embodiment, the feed rate may be not greater than about 2mm/min. It will be appreciated that the feed rate can be within a rangebetween any of the minimum and maximum values above.

In yet another aspect, the abrasive article may be used to slice throughworkpieces including silicon carbide, including single crystal siliconcarbide. For at least one embodiment, the abrasive article can slicethrough the silicon carbide workpiece and exhibit a life of at leastabout 0.1 m²/km, such as at least about 0.2 m²/km, at least about 0.3m²/km, at least about 0.4 m²/km, or even at least about 0.5 m²/km. Insuch instances, the abrasive article may have a particular abrasiveparticle concentration, such as at least about 5 carats per kilometer ofthe substrate, at least about 10 carats per kilometer of substrate, ofat least about 20 carats per kilometer of substrate, at least about 40carats per kilometer of substrate. Still, the concentration may be notgreater than about 300 carats per kilometer of substrate, or even notgreater than about 150 carats per kilometer of substrate. It will beappreciated that the abrasive particle concentration can be within arange between any of the minimum and maximum values above.

The foregoing slicing operation on the workpiece of silicon carbide maybe conducted at a feed rate of at least about 0.05 mm/min, such as atleast about 0.10 mm/min, or even at least about 0.15 mm/min. Still, inone non-limiting embodiment, the feed rate may be not greater than about2 mm/min. It will be appreciated that the feed rate can be within arange between any of the minimum and maximum values above.

Abrasive articles of the embodiments herein have demonstrated improvedabrasive particle retention during use as compared to conventionalabrasive wire saws without at least one of the features of theembodiments herein. For example, the abrasive articles have an abrasiveparticle retention of at least about 2% improvement over one or moreconventional samples. In still other instances, the abrasive particleretention improvement can be at least about 4%, at least about 6%, atleast about 8%, at least about 10%, at least about 12%, at least about14%, at least about 16%, at least about 18%, at least about 20%, atleast about 24%, at least about 28%, at least about 30%, at least about34%, at least about 38%, at least about 40%, at least about 44%, atleast about 48%, or even at least about 50%. Still, in one non-limitingembodiment, the abrasive particle retention improvement can be notgreater than about 100%, such as not greater than about 95%, not greaterthan about 90%, or even not greater than about 80%.

Abrasive articles of the embodiments herein have demonstrated improvedabrasive particle retention and further demonstrated improved useablelife compared to conventional abrasive wire saws without at least one ofthe features of the embodiments herein. For example, the abrasivearticles herein can have an improvement of useable life of at leastabout 2% compared to one or more conventional samples. In still otherinstances, the increase in useable life of an abrasive article of anembodiment herein compared to a conventional article can be at leastabout 4%, at least about 6%, at least about 8%, at least about 10%, atleast about 12%, at least about 14%, at least about 16%, at least about18%, at least about 20%, at least about 24%, at least about 28%, atleast about 30%, at least about 34%, at least about 38%, at least about40%, at least about 44%, at least about 48%, or even at least about 50%.Still, in one non-limiting embodiment, the useable life improvement canbe not greater than about 100%, such as not greater than about 95%, notgreater than about 90%, or even not greater than about 80%.

In accordance with another embodiment, a method of forming abrasivearticles of embodiments described herein may include providing a bodyincluding abrasive particles overlying a first layer, the first layeroverlying a substrate. It will be noted that in certain embodiments, thefirst layer may be referred to as a tacking layer. The method mayfurther include processing at least the substrate, the first layer, andthe abrasive particles according to a controlled processing condition toform an abrasive article having a fillet characteristic.

The fillet characteristic may be selected from the group consisting of atacking factor (t_(fl)/t_(f)), a fillet-to-particle factor(t_(f)/d_(ab)), a fillet-to-bonding layer factor (t_(f)/t_(bl)), acontact factor (A_(b)/A_(f)), a fillet size variance (V_(f)) and acombination thereof. It will be noted that in certain instances, thefillet characteristic can be based upon a predetermined value. It willbe further noted that in other instances, the fillet characteristic maybe related to one or more controlled processing conditions.

The fillet characteristics of the embodiments herein may be calculatedfrom measurements taken from a cross-sectional image of an abrasivearticle. FIG. 18a includes an illustration of a cross-sectional image ofan abrasive article 1800. The illustration of FIG. 18a providesmeasurements that may be taken on a cross-sectional image of anyembodiment of an abrasive article described herein to calculate thefillet characteristics noted herein. Referring to FIG. 18a , theabrasive article 1800 may include a substrate 1810, an abrasive particle1815, a first layer 1820 overlaying the substrate 1810, and a secondlayer 1825 overlaying the first layer 1820 and the abrasive particle1815. Notably, cross-sectional images to be used for calculating thefillet characteristics as described in embodiments herein, arepreferably based upon images where a surface of the abrasive particle1815 is in contact with the substrate 1810 or in contact with the firstlayer 1820. The image may further show fillets 1830, 1832 contacting thesubstrate 1810 and the abrasive particle 1815.

FIG. 18b includes an illustration of a magnified portion of FIG. 18a ,particularly, the portion of abrasive article 1800 near abrasiveparticle 1815.

The substrate 1810 may include a center point 1835, approximatelyequidistance from any point along an outer perimeter 1840 of thesubstrate 1810. A radial axis 1845 may extend outward from the centerpoint 1835 and cross the outer perimeter 1840 of the substrate 1810 atan angle perpendicular to any line tangential to the outer perimeter1940 of the substrate 1810. First layer 1820 may have a thickness d_(fl)measured as the distance along the radial axis 1845 between the outerperimeter 1840 of the substrate 1810 and an outer perimeter 1850 of thefirst layer 1820. The value t_(fl) represents the average thickness offirst layer 1820 calculated from a suitable sample size of d_(fl)measurements made at various locations around the first layer 1820spaced away from the abrasive particle 1815. For instance, in onenon-limiting example, the t_(fl) value may be calculated from a samplesize of greater than about 10 d_(fl) measurements around the first layer1820 spaced away from the abrasive particle 1815.

A radial axis 1855 may extend outward from the center point 1835 andcross the outer perimeter 1840 of the substrate 1810 at an angleperpendicular to any line tangential to the outer perimeter 1840 of thesubstrate 1810. Second layer 1825 may have a thickness d_(bl) measuredas the distance along the radial axis 1855 between the outer perimeter1850 of the first layer 1820 and an outer perimeter 1860 of the secondlayer 1825. The value t_(bl) represents the average thickness of thesecond layer 1825 calculated from a suitable sample size of d_(bl)measurements made at various locations around the second layer 1825spaced away from the abrasive particle 1815. For instance, in onenon-limiting example, the t_(bl) value may be calculated from a samplesize of greater than about 10 d_(bl) measurements around the secondlayer 1825 spaced away from the abrasive particle 1815.

Each abrasive particle 1815, having fillets 1830, 1832, may have asingle d_(f) measurement representing the maximum fillet thickness ofthe abrasive particle 1815. The d_(f) measurement can be the greater ofthe distance between the outer perimeter 1840 of the substrate 1810 anda triple point 1870 or the distance between the outer perimeter 1840 ofthe substrate 1810 and a triple point 1872. It will be appreciated thattriple points 1870, 1872 may be defined as the points of common contactbetween an abrasive particle 1815, fillets 1830 or 1832, and the secondlayer 1825 as viewed in a cross-sectional image. The d_(f) measurementfor an abrasive particle 1815 may be measured along a radial axis 1865that extends from the center point 1835 to whichever of triple points1870 or 1872 is farthest away from the outer perimeter 1840 of substrate1810. For example, referring specifically to FIG. 19, triple point 1870is farther than triple point 1872 from the outer perimeter 1840 ofsubstrate 1810. Therefore, the d_(f) measurement for abrasive particle1815 may be measured along a radial axis 1865 that extends from thecenter point 1835 to triple point 1870. The d_(f) measurement forabrasive particle 1815 is equal to the distance along radial axis 1865between the outer perimeter 1840 of substrate 1810 and triple point1870.

The value t_(f) represents the average maximum fillet thickness for theabrasive article calculated from a statistically relevant sample size ofabrasive particles 1815 and their associated d_(f) measurements. Forinstance, in one non-limiting example, the t_(f) value may be calculatedfrom a sample size of abrasive particles of greater than 10 abrasiveparticles 1815 and their associated d_(f) measurements.

Each abrasive particle 1815 may have an a_(b) measurement thatrepresents the surface area of the abrasive particle 1815 in contactwith the second layer 1825. Each abrasive particle 1815 may also have ana_(f) measurement that represents the surface area of the abrasiveparticle 1815 in contact with the fillets 1830, 1832. The a_(b) anda_(f) measurements may be taken from a cross-sectional image of theabrasive particle 1815 using any suitable imaging instrument, such as ascanning electron microscope, to perform image analysis of the abrasiveparticle 1815.

The value A_(b) represents the average percentage of the surface area ofabrasive particles in contact with the second layer 1825 and may becalculated from a statistically relevant sample size of abrasiveparticles 1815 and their associated a_(b) measurements. For instance, inone non-limiting example, the A_(b) value may be calculated from asample size of greater than 10 abrasive particles 1815 and theirassociated a_(b) measurements. The value A_(f) represents the averagepercentage of the surface area of abrasive particles in contact withfillets 1830, 1832 and may be calculated from a statistically relevantsample size of abrasive particles 1815 and their associated a_(f)measurements. For instance, in one non-limiting example, the A_(f) valuemay be calculated from a sample size of greater than 10 abrasiveparticles 1815 and their associated a_(f) measurements.

The value d_(ab) represents the average particle size of abrasiveparticles in the abrasive article 1800. The average particle size d_(ab)can be a median (D50) or may be represented by the diameter of theparticle as shown in FIGS. 18a and 18b . The value V_(f) represents thefillet size variance (V_(f)) and may be expressed mathematically as[(Fmax−Favg)/Fmax]×100%. Fmax represents a greatest value of filletthickness of a sample and Favg represents the average maximum thicknessof the fillets of a sample.

It will be appreciated that abrasive particles 1815 may be coatedabrasive particles as described herein. For purposes of determiningfillet factors according to embodiments disclosed herein, any suchcoating on an abrasive particle up to and including a thickness of about0.3 μm from the surface of the abrasive particle will be considered partof the abrasive particle. Therefore, for purposes of any measurements,including, but not limited to, t_(fl), t_(bl), t_(f), D_(ab), A_(b), orA_(f), any coating of the abrasive particle 1815, for example, a tincoating, up to and including a thickness of about 0.3 μm from thesurface of the abrasive particle, will not be considered or included inthe required measurements. Further, in certain embodiments, it will beappreciated that the triple point may be defined as the points of commoncontact between a coating of an abrasive particle 1815 up to andincluding a thickness of about 0.3 μm from the surface of the abrasiveparticle, fillets 1830 or 1832, and the second layer 1825 as viewed in across-sectional image.

It will be further appreciated that all average values described herein,for example, t_(fl), t_(bl), t_(f), d_(ab), A_(b) or A_(f), may alsorefer to mean values or median values. For example, d_(ab) can be amedian (D50) value of the abrasive particles of the abrasive article. Itwill be further appreciated that all averages described herein may becalculated from a suitable sample size of values, for example, a samplesize of greater than about 10 values.

It will be further appreciated that the measurements noted herein fordetermining fillet characteristics may be taken from cross-sectionalimages of abrasive articles under a magnification in the range of 100×to about 1000×. It will be further appreciated that the measurementsnoted herein for determining fillet characteristics may be preferablytaken from cross-sectional images of abrasive articles under amagnification of about 300×.

It will be further appreciated that the fillet characteristics notedabove may be related to one or more controlled processing conditions. Incertain embodiments, the fillet characteristic may be selected based oncontrol of one or more controlled processing conditions. In still otherembodiments, the fillet characteristic can be a predetermined filletcharacteristic, which may be based upon a user-selected value prior toforming the abrasive article and which may be determined based uponcontrol of one or more controlled processing conditions.

Accordingly to particular embodiments, the one or more controlledprocessing condition may be selected from the group consisting ofre-flow temperature, filler content, filler size, filler composition,average particle size of the abrasive particles, size distribution ofthe abrasive particles, content of the abrasive particles, compositionof the abrasive particles, thickness of the first layer, composition ofthe first layer, atmospheric conditions, and a combination thereof. Incertain embodiments, the one or more controlled processing condition,for example, re-flow temperature, may be user controlled to control afillet characteristic, for example a tacking factor (t_(fl)/t_(f)) forthe abrasive article. The value of the fillet characteristic may thus beuser controlled or selected based upon an expected or predeterminedabrasive application, for example, diamond wire for sapphire or siliconwafer sawing.

According to a particular embodiment, the expected or predeterminedabrasive application may be based upon at least one parameter selectedfrom the group consisting of a workpiece hardness, a workpiece size,workpiece composition, abrasive article life, abrasive particleretention strength, cutting force an workpiece quality.

In a particular embodiment, the fillet characteristic may be a tackingfactor expressed mathematically as t_(fl)/t_(f). In certain non-limitingembodiments, the tacking factor may be at least about 0.01, such as, atleast about 0.02, at least about 0.03, at least about 0.04, at leastabout 0.05, at least about 0.1, at least about 0.2, at least about 0.3,at least about 0.4, at least about 0.5, at least about 0.6, at leastabout 0.7, at least about 0.8, at least about 0.9, at least about 1.0,at least about 1.1, at least about 1.2, at least about 1.3, at leastabout 1.4, at least about 1.5, at least about 1.6, at least about 1.7,at least about 1.8 or even at least about 1.9. In still othernon-limiting embodiments, the tacking factor may be not greater thanabout 2, such as, not greater than about 1.9, not greater than about1.8, not greater than about 1.7, not greater than about 1.6, not greaterthan about 1.5, not greater than about 1.4, not greater than about 1.3,not greater than about 1.2, not greater than about 1.1, not greater thanabout 1, not greater than about 0.9, not greater than about 0.8, notgreater than about 0.7, not greater than about 0.6, not greater thanabout 0.5, not greater than about 0.4, not greater than about 0.3 oreven not greater than about 0.2. It will be appreciated that the tackingfactor may be any value within a range between any of the minimum andmaximum values noted above.

According to another particular embodiment, the fillet characteristicmay be a fillet-to-particle factor expressed mathematically ast_(f)/d_(ab). In certain non-limiting embodiments, thefillet-to-particle factor may be at least about 0.01, such as, at leastabout 0.02, at least about 0.03, at least about 0.04, at least about0.05, at least about 0.06, at least about, at least about 0.08, at leastabout 0.1, at least about 0.12, at least about 0.15, at least about 0.2,at least about 0.25, at least about 0.3, at least about 0.35, at leastabout 0.4, at least about 0.45, at least about 0.5 or even at leastabout 0.55. In still other non-limiting embodiments, thefillet-to-particle factor may be not greater than about 1, such as, notgreater than about 0.95, not greater than about 0.9, not greater thanabout 0.85, not greater than about 0.80, not greater than about 0.75,not greater than about 0.7, not greater than about 0.7, not greater thanabout 0.65, or even not greater than about 0.6. It will be appreciatedthat the fillet-to-particle factor may be any value within a rangebetween any of the minimum and maximum values noted above.

According to another particular embodiment, the fillet characteristicmay be a contact factor expressed mathematically as A_(b)/A_(f). Incertain non-limiting embodiments, the contact factor may be not greaterthan about 100, such as, not greater than about 95, not greater thanabout 90, not greater than about 85, not greater than about 80, notgreater than about 75, not greater than about 70, not greater than about65, not greater than about 60, not greater than about 55, not greaterthan about 50, not greater than about 45, not greater than about 40, notgreater than about 35, not greater than about 30, not greater than about25, not greater than about 20, not greater than about 15 or even notgreater than about 10. In still other non-limiting embodiments, thecontact factor may be at least about 0.01, such as, at least about 0.02,at least about 0.05, at least about 0.08, at least about 0.1, at leastabout 0.15, at least about 0.2, at least about 0.25, at least about 0.3,at least about 0.35, at least about 0.4, at least about 0.45, at leastabout 0.5, at least about 0.55, at least about 0.6, at least about 0.65,at least about 0.7, at least about 0.75, at least about 0.8, at leastabout 0.85, at least about 0.9 or even at least about 0.95. It will beappreciated that the contact factor may be any value within a rangebetween any of the minimum and maximum values noted above.

According to another particular embodiment, the fillet characteristicmay be a fillet-to-bonding layer factor expressed mathematically ast_(f)/t_(bl). In certain non-limiting embodiments, the fillet-to-bondinglayer factor may be at least about 0.01, such as, at least about 0.02,at least about 0.05, at least about 0.1, at least about 0.15, at leastabout 0.2, at least about 0.25, at least about 0.3, at least about 0.35,at least about 0.4, at least about 0.45, or even at least about 0.5. Instill other non-limiting embodiments, the fillet-to-bonding layer factormay be not greater than about 100, such as, not greater than about 80,not greater than about 60, not greater than about 40, not greater thanabout 20, not greater than about 10, not greater than about 5, notgreater than about 4, not greater than about 3.5, not greater than about3, not greater than about 2.8, not greater than about 2.6, not greaterthan about 2.4, not greater than about 2.2, not greater than about 2,not greater than about 1.9, not greater than about 1.8, not greater thanabout 1.7, not greater than about 1.6, not greater than about 1.5, notgreater than about 1.4, not greater than about 1.3, not greater thanabout 1.2 or even not greater than about 1.1. It will be appreciatedthat the fillet-to-bonding layer factor may be any value within a rangebetween any of the minimum and maximum values noted above.

According to another particular embodiment, the fillet characteristicmay be the fillet size variance (V_(f)) expressed mathematically as[(Fmax−t_(f))/Fmax]×100%. Fmax represents a greatest value of filletthickness of a sampling and t_(f) is an average maximum fillet size asdescribed herein. It will be appreciated that a sampling is reference toa statistical sample size of fillets taken from the abrasive article ofa suitable number to derive a statistically relevant average. As notedherein, in one non-limiting example, the sampling can include at least10 different measurements. In certain non-limiting embodiments, thefillet size variance (V_(f)) may be not greater than about 95%, such as,not greater than about 93%, not greater than about 90%, not greater thanabout 88%, not greater than about 85%, not greater than about 83%, notgreater than about 80%, not greater than about 78%, not greater thanabout 75%, not greater than about 73%, not greater than about 70%, notgreater than about 68%, not greater than about 65%, not greater thanabout 63%, not greater than about 60%, not greater than about 58%, notgreater than about 55%, not greater than about 53%, not greater thanabout 50%, not greater than about 48%, not greater than about 45%, notgreater than about 43%, not greater than about 40%, not greater thanabout 30%, not greater than about 20%, not greater than about 10%. Instill other non-limiting embodiments, the fillet size variance (V_(f))may be at least about 2%, at least about 5%, at least about 10%, atleast about 20%, at least about 30%, at least about 40% or even at leastabout 50%. It will be appreciated that the fillet size variance (V_(f))may be any percentage within a range between any of the minimum andmaximum percentages noted above

In other embodiments, the abrasive article may further including acombination of at least two fillet characteristics from the groupconsisting of a tacking factor (t_(fl)/t_(f)), a fillet-to-particlefactor (t_(f)/d_(ab)), a fillet-to-bonding layer factor (t_(f)/t_(bl)),a contact factor (A_(b)/A_(f)) or a fillet size variance (V_(f)).

As noted above, the fillet characteristic may be selected from the groupconsisting of fillet characteristics having predetermined values. Forexample, the fillet characteristic may be selected from the groupconsisting of a tacking factor (t_(fl)/t_(f)) of not greater than about1.5, a fillet-to-particle factor (t_(f)/d_(ab)) of not greater thanabout 0.33, a fillet-to-bonding layer factor (t_(f)/t_(bl)) of notgreater than about 100, a contact factor (A_(b)/A_(f)) of at least about1, a fillet size variance (V_(f)) of not greater than 60% or acombination thereof. It will be noted that in certain instances, thefillet characteristic can be based upon a predetermined value. It willbe further noted that in other instances, the fillet characteristic maybe related to one or more controlled processing conditions.

In certain embodiments, the one or more controlled processing condition,for example, re-flow temperature, may be user controlled to produce thedesired fillet characteristic having the predetermined value, forexample a tacking factor (t_(fl)/t_(f)) of not greater than about 1.5.

According to another particular embodiment, the desired filletcharacteristic may be a tacking factor, expressed mathematically ast_(fl)/t_(f), of not greater than about 1.5. For example, in certainnon-limiting embodiments, the tacking factor may be not greater thanabout 1.4, not greater than about 1.3, not greater than about 1.2, notgreater than about 1.1, not greater than about 1, not greater than about0.99, not greater than about 0.97, not greater than about 0.95, notgreater than about 0.92, not greater than about 0.9, not greater thanabout 0.85, not greater than about 0.8, not greater than about 0.75, notgreater than about 0.7, not greater than about 0.65, not greater thanabout 0.6, not greater than about 0.55 or even not greater than about0.51. In other non-limiting embodiments, the tacking factor may be atleast about 0.5, such as, at least about 0.55, at least about 0.6, atleast about 0.65, at least about 0.7, at least about 0.75, at leastabout 0.8, at least about 0.85, at least about 0.9, at least about 0.92,at least about 0.95, at least about 0.97, at least about 0.99, at leastabout 1, at least about 1.1, at least about 1.2, at least about 1.3 oreven at least about 1.4. It will be appreciated that the tacking factormay be any value within a range between any of the minimum and maximumvalues noted above.

According to another particular embodiment, the desired filletcharacteristic may be a fillet-to-particle factor, expressedmathematically as t_(f)/d_(ab), of not greater than about 0.33. Forexample, in certain non-limiting embodiments, the fillet-to-particlefactor may be not greater than about 0.31, not greater than about 0.3,not greater than about 0.27, not greater than about 0.25, not greaterthan about 0.23, not greater than about 0.2, not greater than about0.17, not greater than about 0.15, not greater than about 0.13, notgreater than about 0.1, not greater than about 0.07 or even not greaterthan about 0.06. In other non-limiting embodiments, thefillet-to-particle factor may be at least about 0.05, such as, at leastabout 0.07, at least about 0.1, at least about 0.12, at least about0.14, at least about 0.16, at least about 0.18, at least about 0.20, atleast about 0.24, at least about 0.26, at least about 0.28, at leastabout 0.30 or even at least about 0.32. It will be appreciated that thefillet-to-particle factor may be any value within a range between any ofthe minimum and maximum values noted above.

According to another particular embodiment, the desired filletcharacteristic may be a fillet-to-bonding layer factor, expressedmathematically as t_(f)/t_(bl), of not greater than about 100. Forexample, in certain non-limiting embodiments, the fillet-to-bondinglayer factor may be not greater than about 90, not greater than about80, not greater than about 70, not greater than about 60, not greaterthan about 50, not greater than about 40, not greater than about 35, notgreater than about 30, not greater than about 28, not greater than about26, not greater than about 24, not greater than about 22, not greaterthan about 20, not greater than about 18, not greater than about 16, notgreater than about 14, not greater than about 12 or even not greaterthan about 11. In non-limiting embodiments, the fillet-to-bonding layerfactor may be at least about 10, such as, at least about 12, at leastabout 14, at least about 16, at least about 18, at least about 20, atleast about 22, at least about 24, at least about 26, at least about 28,at least about 30, at least about 35, at least about 40, at least about45, at least about 50, at least about 60, at least about 70, at leastabout 80, at least about 90 or even at least about 95. It will beappreciated that the fillet-to-bonding layer factor may be any valuewithin a range between any of the minimum and maximum values notedabove.

According to another particular embodiment, the desired filletcharacteristic may be a contact factor, expressed mathematically asA_(b)/A_(f), of at least about 1.0. For example, in certain non-limitingembodiments, the contact factor may be at least about 1.2, at leastabout 1.4, at least about 1.5, at least about 1.6, at least about 1.7,at least about 1.8, at least about 1.9, at least about 2, at least about2.2, at least about 2.4, at least about 2.6, at least about 2.8, atleast about 3, at least about 3.5, at least about 4, at least about 5,at least about 6, at least about 7, at least about 8 or even at leastabout 9. In other non-limiting embodiments, the contact factor may benot greater than about 10, such as, not greater than about 9, notgreater than about 8, not greater than about 7, not greater than about6, not greater than about 5, not greater than about 4, not greater thanabout 3.5, not greater than about 3, not greater than about 2.8, notgreater than about 2.6, not greater than about 2.4, not greater thanabout 2.3, not greater than about 2.2, not greater than about 2, notgreater than about 1.9, not greater than about 1.8, not greater thanabout 1.7, not greater than about 1.6, not greater than about 1.5, notgreater than about 1.4, not greater than about 1.3, not greater thanabout 1.2 or even not greater than about 1.1. It will be appreciatedthat the contact factor may be any value within a range between any ofthe minimum and maximum values noted above.

According to another particular embodiment, the fillet characteristicmay be the fillet size variance (V_(f)) expressed mathematically as[(Fmax−t_(f))/Fmax]×100%. Fmax represents a greatest value of filletthickness of a sampling and t_(f) is an average maximum fillet size asdescribed herein. It will be appreciated that a sampling is reference toa statistical sample size of fillets taken from the abrasive article ofa suitable number to derive a statistically relevant average. As notedherein, in one non-limiting example, the sampling can include at least10 different measurements. In certain non-limiting embodiments, thefillet size variance (V_(f)) may be not greater than about 60%, such as,not greater than about 58%, not greater than about 55%, not greater thanabout 53%, not greater than about 50%, not greater than about 48%, notgreater than about 45%, not greater than about 43%, not greater thanabout 40%, not greater than about 30%, not greater than about 20%, notgreater than about 10%, not greater than about 8%, not greater thanabout 6%, not greater than about 4% or even not greater than about 3%.In still other non-limiting embodiments, the fillet size variance(V_(f)) may be at least about 2%, at least about 5%, at least about 10%,at least about 20%, at least about 30%, at least about 40% or even atleast about 50%. It will be appreciated that the fillet size variance(V_(f)) may be any percentage within a range between any of the minimumand maximum percentages noted above.

In other embodiments, the abrasive article may further including acombination of at least two desired fillet characteristics havingpredetermined values selected from the group consisting of a tackingfactor (t_(fl)/t_(f)) of not greater than about 1.5, afillet-to-particle factor (t_(f)/d_(ab)) of not greater than about 0.33,a fillet-to-bonding layer factor (t_(f)/t_(bl)) of not greater thanabout 100, a contact factor (A_(b)/A_(f)) of at least about 1, a filletsize variance (V_(f)) of not greater than 60%.

According to another particular embodiment, the fillets may include acomposition that is substantially the same as a composition of the firstlayer. In still other embodiments, the fillets may have a compositionthat is essentially the same as a composition of the first layer. In yetanother embodiment, the fillets may include a composition having adifference in elemental composition of not greater than about 5 wt. %for any element compared to a composition of the first layer. Such as,for example, not greater than about 4 wt. %, not greater than about 3wt. %, or even not greater than about 1 wt. % for a single elementbetween the composition of the fillet and the composition of the firstlayer. It will be appreciated, that such a feature as the difference incomposition between the first layer (i.e., the tacking layer) and thefillet may also exist between the fillet and the second layer (i.e., thebonding layer). It will be appreciated, that such a feature as thedifference in composition between the first layer and the fillet mayalso exist between the fillet and a barrier layer.

According to another particular embodiment, the fillets may include acomposition that is substantially different from a composition of thefirst layer. In still other embodiments, the fillets may have acomposition that includes at least one element different than an elementof the first layer. In yet another embodiment, the fillets may have acomposition having a difference in elemental composition of at leastabout 5 wt. % for any element compared to a composition of the firstlayer. Such as, for example, at least about 6 wt. %, at least about 7wt. %, at least about 8 wt. %, at least about 9 wt. %, at least about 10wt. %, at least about 15 wt. %, at least about 20 wt. %, at least about40 wt. % or even at least about 50 wt. % for a single element betweenthe composition of the fillet and the composition of the first layer. Itwill be appreciated, that such a feature as the difference incomposition between the first layer (i.e., the tacking layer) and thefillet may also exist between the fillet and the second layer (i.e., thebonding layer). It will be appreciated, that such a feature as thedifference in composition between the first layer and the fillet mayalso exist between the fillet and a barrier layer.

According to another embodiment, the fillets may include an activebonding material. The active bonding material may include a materialselected from the group consisting of borides, oxides, nitrides,carbides, oxynitrides, oxyborides, oxycarbides, and a combinationthereof. For example, in one embodiment, the fillets may include anactive bonding material including titanium. In another non-limitingembodiment, the fillets may include an active bonding material includingtitanium carbide.

According to another embodiment, the fillets may include a metal. In yetanother embodiment, the fillets may include a metal alloy. In stillanother embodiment, the fillets may include an elemental metal. In yetanother embodiment, the fillets may include one or more transition metalelements. For example, in certain instances, the fillets may includetin. In yet another embodiment, the fillets can include copper. In stillanother embodiment, the fillets may include nickel. In still anotherembodiment, the fillets may include solder. In still another embodiment,the fillets may include a mixture of tin and copper.

According to another embodiment, the fillets may include a mixture of acomposition of the first layer and an active bonding material. In stillanother embodiment, the fillets may include at least two discrete phasesof material. For example, the fillets may include a first phase and asecond phase. In certain instances, the first phase may bepreferentially located closer to a surface of the abrasive particles ascompared to the second phase. In still other instances, the first phasepreferentially located closer to a surface of the abrasive particle maybe a material including the active bonding material or an element fromthe active bonding material, while the second phase, which is discretefrom the first phase and has a separate composition compared to thefirst phase may, in some instances, be absent any elements of the activebonding material. In yet another embodiment, the fillets may include atleast three discrete phases of material, including a first phase, asecond phase, and a third phase.

According to another embodiment, the fillets may extend from the firstlayer. In other embodiments, the fillets may be integral with the firstlayer. In still other embodiments, the fillets may form an amalgamatewith the first layer.

According to another embodiment the abrasive article may include afiller, which may be present in at least the first layer, oralternatively, may be present exclusively in the first layer. The fillermay be distinct from the abrasive particles. In other embodiments, thefiller may be distinct from the abrasive particles based on at least onefiller criteria selected from the group consisting of average particlesize, composition, content, concentration, distribution, and acombination thereof.

According to yet another embodiment, the abrasive particles may have anaverage particle size (P1) and the filler may have an average particlesize (F1). In certain embodiments, the average particle size of theabrasive particles may be greater than the average particle size of thefiller. In other embodiments, the average particle size of the abrasiveparticles may be at least about 5% different than the average particlesize of the filler based on the equation ((P1−F1)/P1)×100%. In stillother embodiments, the average particle size of the abrasive particlesmay be at least about 10% different, at least about 20% different, atleast about 30% different, at least about 40% different, at least about50% different, at least about 60% different, at least about 70%different, at least about 80% different, at least about 90% different oreven at least about 95% different. In still other embodiments, theaverage particle size of the abrasive particles may not greater thanabout 99% different, such as, not greater than about 95% different, notgreater than about 90% different, not greater than about 80% different,not greater than about 70% different, not greater than about 60%different, not greater than about 50% different, not greater than about50% different, not greater than about 40% different, not greater thanabout 30% different, not greater than about 20% different or even notgreater than about 10% different. It will be appreciated percentagedifference between the average particle size of the abrasive particlesand the average particle size of the filler may be any value within arange between any of the maximum and minimum values noted above.

According to another embodiment, the filler may have an average particlesize of not greater than about 500 microns, such as, not greater thanabout 300 microns, not greater than about 200 microns, not greater thanabout 150 microns, not greater than about 100 microns, not greater thanabout 80 microns, not greater than about 50 microns, not greater thanabout 30 microns, not greater than about 20 microns, not greater thanabout 15 microns, not greater than about 12 microns, not greater thanabout 10 microns or even not greater than about 8 microns. In otherembodiments, the filler may have an average particle size of at leastabout 0.01 microns, such as, at least about 0.05 microns, at least about0.1 microns, at least about 0.5 microns, at least about 1 microns, atleast about 3 microns, at least about 5 microns, at least about 8microns, or even at least about 10 microns. It will be appreciated thatthe filler may have an average particle size of any value within a rangeof any of the minimum and maximum values noted above.

According to yet another embodiment, the filler may include a materialselected from the group consisting of an inorganic material, an organicmaterial, a polymer, a synthetic material, a natural material, and acombination thereof. In still another embodiment, the filler may includea material selected from the group consisting of a thermoplasticmaterial, a thermoset material, a resin, a ceramic, a glass, a metal, ametal alloy, a metal coated particle, a substantially spherical bead, ahollow body, an elongated body, a fiber, and a combination thereof. Ityet another embodiment, the filler may include a material selected fromthe group consisting of an oxide, a carbide, a nitride, a boride,diamond, a carbon-based material, cubic boron nitride, and a combinationthereof.

According to another embodiment, the filler may include a Vickershardness of at least about 0.1 GPa, such as, at least about 1 GPa oreven at least about 3 GPa. In still another embodiment, the filler mayinclude a Vickers hardness of not greater than about 200 GPa, such as,not greater than about 150 GPa or even not greater than about 100 GPa.It will be appreciated that the filler may have a Vickers hardness ofany value within a range between any of the minimum and maximum valuesnoted above.

According to another embodiment, the abrasive particles may have anaverage hardness (Hap) and the filler may have an average hardness (Hf).The average hardness of the abrasive particles (Hap) may be greater thanthe average hardness of the filler (Hf). In other embodiments, theaverage hardness of the abrasive particles may be at least about 5%different than the average hardness of the filler based on the equation((Hap−Hf)/Hap)×100%. In still other embodiments, the average hardness ofthe abrasive particles may be at least about 10% different, at leastabout 20% different, at least about 30% different, at least about 40%different, at least about 50% different, at least about 60% different,at least about 70% different, at least about 80% different or even atleast about 90% different than the average hardness of the filler. Inyet other embodiments, the average hardness of the abrasive particlesmay be not greater than about 99% different, not greater tan about 90%different, not greater than about 80% different, not greater than about70% different, not greater than about 60% different, not greater thanabout 60% different, not greater than about 50% different, not greaterthan about 40% different, not greater than about 30% different, or even,not greater than about 20% different than the average hardness of thefiller. It will be appreciated that the percentage difference betweenthe average hardness of the abrasive particles and the average hardnessof the filler may be any value within a range between any of the minimumand maximum values noted above.

According to still another embodiment, the filler may have a fillercomposition distinct from an abrasive particle composition. In otherembodiments, the filler composition may be different from the abrasiveparticle composition by at least 5 wt. % of at least one element withinthe filler composition and the abrasive particle composition.

According to yet another embodiment, the abrasive particles may bepresent in an abrasive particle content and the filler may be present ina filler content. The abrasive article may include an abrasive particlecontent greater than a filler content. In other embodiments, the fillercontent may be greater than the abrasive particle content. In stillother embodiments, the abrasive particle content may be substantiallythe same as the filler content. In still other embodiments, the abrasivearticle may include a particle count ratio (Cap:Cf) of abrasive particlecontent (Cap) to filler content (Cf) of not greater than about 100:1,such as, not greater than about 50:1, not greater than about 20:1, notgreater than about 10:1, not greater than about 5:1, not greater thanabout 2:1, or even about 1:1. In yet other embodiments, the particlecount ratio (Cap:Cf) may be at least about 2:1, such as, at least about5:1, at least about 10:1, at least about 20:1, at least about 50:1 oreven at least about 100:1. It will be appreciated that the particlecount ratio (Cap:Cf) may be any value within a range between any of theminimum and maximum values noted above.

In another embodiment, the concentration of filler on the elongatedabrasive article can be at least about 0.00001 gram per meter, at leastabout 0.00002 gram per meter, at least about 0.00005 gram per meter, atleast about 0.0001 gram per meter, at least about 0.0002 gram per meter,at least about 0.0005 gram per meter, at least about 0.001 gram permeter, at least about 0.002 gram per meter, at least about 0.005 gramper meter or even at least about 0.001 gram per meter. In still otherembodiments, the concentration of filler on the elongate abrasivearticle can be not greater than about 0.1 gram per meter, not greaterthan about 0.05 gram per meter, not greater than about 0.02 gram permeter, not greater than about 0.01 gram per meter, not greater thanabout 0.005 gram per meter, not greater than about 0.002 gram per meter,or even not greater than about 0.001 gram per meter. It will beappreciated that the concentration of filler on the elongated abrasivearticle may be any value within a range between any of the minimum andmaximum values noted above.

In other embodiments, the filler may have a greater wetting affinity fora composition of the first layer as compared to a wetting affinity ofthe abrasive particles.

For at least one embodiment, a particular method of forming may beutilized including one or more controlled processing conditions tofacilitate formation of an abrasive article having particular filletcharacteristics according to the embodiments herein. The process may beinitiated as described generally in embodiments herein, with theformation of a first layer (e.g., a tacking layer) on the substrate, andplacement of abrasive particles on the first layer. In accordance withone embodiment, one or more controlled processing conditions can beapplied, which can facilitate certain fillet characteristics accordingto embodiments herein. For example, the controlled processing conditionmay include heating the substrate, the first layer, and the abrasiveparticles to a re-flow temperature. Heating the substrate, the firstlayer and the abrasive particles may include selecting a re-flowtemperature and a viscosity, and controlling the wetting of the firstlayer on the abrasive particles. Heating the substrate, the first layerand the abrasive particles may further include selecting a re-flowtemperature corresponding to a predetermined viscosity to control thewetting of the first layer on the abrasive particles and controlling theaverage maximum thickness of the fillets.

In other embodiments, the re-flow temperature may be different from amelting temperature of the first layer. In still other embodiments, there-flow temperature may be different than the melting temperature by atleast about 0.5% based on the equation [(Tm−Tr)/Tm]×100%. Tm representsthe melting temperature and Tr represents the re-flow temperature. Inother embodiments the re-flow temperature may be different than themelting temperature by at least about 1%, at least about 2%, at leastabout 3%, at least about 4%, at least about 5%, at least about 8%, atleast about 10%, at least about 12%, at least about 15%, at least about20%, at least about 30% or even at least about 40%. In still otherembodiments, the re-flow temperature may be different than the meltingtemperature by not greater than about 80%, not greater than about 70%,not greater than about 60%, not greater than about 50%, not greater thanabout 40%, not greater than about 30%, not greater than about 20%, notgreater than about 16%, not greater than about 14%, not greater thanabout 12%, not greater than about 10%, not greater than about 8% oreven, not greater than about 6%. It will be appreciated that the re-flowtemperature may be different than the melting temperature by anypercentage within a range between any of the minimum and maximum valuesnoted above.

According to other embodiments, the re-flow temperature may be notgreater than about 450° C., such as, not greater than about 440° C., notgreater than about 430° C., not greater than about 420° C., not greaterthan about 410° C., not greater than about 400° C., not greater thanabout 390° C., not greater than about 380° C., not greater than about370° C., not greater than about 360° C., not greater than about 350° C.,not greater than about 340° C., not greater than about 330° C., notgreater than about 320° C., not greater than about 310° C. or even notgreater than about 300° C. In other embodiments, the re-flow temperatureis at least about 100° C., such as, at least about 120° C., at leastabout 150° C., at least about 180° C., at least about 200° C. or even atleast about 220° C. It will be appreciated that the re-flow temperaturemay be any value within a range between any minimum or maximum valuenoted above.

According to other embodiments, processing according to the controlledprocessing condition may include changing a viscosity of the first layerand controlling the wetting of the abrasive particles by the firstlayer. Processing according to the controlled processing condition mayfurther include increasing a viscosity of the first layer andcontrolling the amount of wetting of the abrasive particles by the firstlayer.

According to still other embodiments, processing according to thecontrolled processing condition may include providing a filler tocontrol the wetting of the first layer on the abrasive particles.Processing according to the controlled processing condition may includeselecting at least one of a filler composition, a filler size, and afiller content to control the wetting of the first layer on the abrasiveparticles. In other embodiments, processing according to the controlledprocessing condition may include providing a filler to control theaverage maximum thickness of the fillets.

In other embodiments, processing according to the controlled processingcondition may include providing an atmospheric condition selected fromthe group consisting of a reducing atmosphere, an oxidizing atmosphere,an inert atmosphere, an atmosphere consisting essentially of oneelement, and a combination thereof.

According to other embodiments, the first layer may be configured to bea tacking layer. The tacking layer may provisionally hold the abrasiveparticles in place during processing. In other embodiments, the firstlayer may be in direct contact with a surface of the substrate.

According to other embodiments, the first layer may have an averagethickness of not greater than about 80% of an average particle size ofthe abrasive particles. For example, in certain embodiments, the firstlayer may have an average thickness of not greater than about 70% oreven not greater than about 40% of an average particle size of theabrasive particles. In still other embodiments, the first layer may havean average thickness of at least about 2%, such as, at least about 5%,at least about 6%, at least about 7%, at least about 8%, at least about9%, at least about 10%, at least about 11%, at least about 12% or even,at least about 13% of an average particle size of the abrasiveparticles. It will be appreciated the average thickness of the firstlayer relative to the average particle size of the abrasive particlesmay be any value within a range between any of the minimum and maximumvalues noted above.

According to other particular embodiments, at least a portion of theabrasive particles may be spaced apart from an upper surface of thesubstrate. In still other embodiments, a majority of the abrasiveparticles may be spaced apart from an upper surface of the substrate.

In still other embodiments, the abrasive article may include undercutregions between an abrasive particle and a substrate. Undercut regionsmay be defined as either 1) a region of the second layer (e.g., thebonding layer) along a radial axis between an outermost point on anabrasive particle and the center point of the substrate, or 2) a regionof void or empty space along a radial axis between an outermost point anabrasive particle and the center point of the core.

FIG. 19a includes an illustration of a cross-sectional image of anabrasive article 1900 having undercut regions between the abrasiveparticle and the substrate determined by the presence of the secondlayer between an outermost point on an abrasive particle and the centerpoint of the substrate. Referring to FIG. 19a , the abrasive article1900 may include a substrate 1910, an abrasive particle 1915, a firstlayer 1920 overlaying the substrate 1910, and a second layer 1925overlaying the first layer 1920 and the abrasive particle 1915. Theimage may further show undercut regions 1930, 1932 between the abrasiveparticle 1915 and the substrate 1910. The substrate 1910 may include acenter point 1935, equidistance from any point along an outer perimeter1940 of the substrate 1910. A radial axis 1945 may extend outward fromthe center point 1935 to an outermost point 1947 on the abrasiveparticle 1915. The abrasive article 1900 as illustrated in FIG. 19a maybe determined to have undercut regions 1930, 1932 wherein the radialaxis 1945 passes through second layer 1925 between outermost point 1947and center point 1935.

FIG. 19b includes an illustration of a magnified portion of FIG. 19a ,particularly, the undercut region 1930 between the abrasive particle1915 and the substrate 1910.

FIG. 20a includes an illustration of a cross-sectional image of anabrasive article 1950 having undercut regions between the abrasiveparticle and the substrate determined by the presence of a void or emptyspace between an outermost point on an abrasive particle and the centerpoint of the substrate. Referring to FIG. 20a , the abrasive article1950 may include a substrate 1960, an abrasive particle 1965, a firstlayer 1970 overlaying the substrate 1965, and a second layer 1975overlaying the first layer 1970 and the abrasive particle 1965. Theimage may further show undercut regions 1980, 1982 between the abrasiveparticle 1965 and the substrate 1960. The substrate 1960 may include acenter point 1985, equidistance from any point along an outer perimeter1990 of the substrate 1960. A radial axis 1995 may extend outward fromthe center point 1985 to an outermost point 1997 on the abrasiveparticle 1965. The abrasive article 1950 as illustrated in FIG. 20a maybe determined to have undercut regions 1930, 1932 wherein the radialaxis 1995 passes through an open space or void area between outermostpoint 1997 and center point 1985.

FIG. 20b includes an illustration of a magnified portion of FIG. 20a ,particularly, the undercut region 1980 between the abrasive particle1965 and the substrate 1960.

According to other embodiments, at least about 55% of the abrasiveparticles may have an undercut region. In other embodiments, at leastabout 60%, of the abrasive particles may have an undercut region, suchas, at least about 70%, at least about 80%, at least about 90% or evenat least about 95% of the abrasive particles have an undercut region. Instill other embodiments, not greater than about 99% of the abrasiveparticles may have an undercut region, such as, not greater than about95%, not greater than about 90%, not greater than about 80%, not greaterthan about 70%, not greater than about 70%, not greater than about oreven, not greater than about 60% of the abrasive particles have anundercut region. It will be appreciated that the percent of the abrasiveparticles that may have an undercut region may be any percentage withina range between any of the minimum and maximum values noted above.

EXAMPLE 1

A length of high strength carbon steel wire is obtained as a substrate.The high strength carbon steel wire has an average diameter ofapproximately 180 microns. A first layer is formed on the externalsurface of the substrate via electroplating. The electroplating processforms a first layer having an average thickness of approximately 3.75microns. The first layer is formed of an essentially pure tincomposition.

After forming the first layer, flux material is applied on the wire withnickel-coated diamond abrasive particles having an average particle sizeof between 30 to 40 microns.

Thereafter, the substrate, first layer, and abrasive particles undergotin re-flow heating (diamond tacking) in a furnace at a temperaturesufficient to heat the first layer to a re-flow temperature between 30°C. and 50° C. above the melting temperature of the first layer (i.e.,melting temperature for tin is 232° C.). The abrasive pre-form is thencooled and rinsed. The process of bonding the nickel coated diamond tothe first layer is conducted at an average spooling rate of 20 m/min.

Thereafter, the abrasive pre-form is washed using 20 wt % Sulfuric acidfollowed by a rinse with de-ionized water. The rinsed article iselectroplated with nickel to form a bonding layer directly contactingand overlying the abrasive particles and first layer. FIG. 21 includes ascanning electron microscopy of a portion of the abrasive article formedfrom the process of Example 1 taken at a magnification of 300×.

During the high temperature re-flow, the tin layer segregates aroundnickel coated diamond particles and forms large filets connectingdiamond particles to the wire. The abrasive article has a tacking factor(t_(fl)/t_(f)) of about 0.05, a fillet-to-particle factor (t_(f)/d_(ab))of about 0.8, a fillet-to-bonding layer factor (t_(f)/t_(bl)) of 3, acontact factor (A_(b)/A_(f)) of about 0.3.

EXAMPLE 2

A length of high strength carbon steel wire is obtained as a substrate.The high strength carbon steel wire has an average diameter ofapproximately 180 microns. A first layer is formed on the externalsurface of the substrate via electroplating. The electroplating processforms a first layer having an average thickness of approximately 3.75microns. The first layer is formed of an essentially pure tincomposition.

After forming the first layer, flux material is applied on the wire withnickel-coated diamond abrasive particles having an average particle sizeof between 30 to 40 microns.

Thereafter, the substrate, first layer, and abrasive particles undergotin re-flow heating (diamond tacking) in a furnace at a temperaturesufficient to heat the first layer to a re-flow temperature between 1°C. and 10° C. above the melting temperature of the first layer (i.e.,melting temperature for tin is 232° C.). The abrasive pre-form is thencooled and rinsed. The process of bonding the nickel coated diamond tothe first layer is conducted at an average spooling rate of 20 m/min.

Thereafter, the abrasive pre-form is washed using 20 wt % Sulfuricfollowed by a rinse with de-ionized water. The rinsed article iselectroplated with nickel to form a bonding layer directly contactingand overlying the abrasive particles and first layer. FIG. 22 includesscanning electron microscopy of a portion of the abrasive article formedfrom the process of Example 2 taken at a magnification of 300×.

Because the re-flow is done under relatively low temperature, the tinlayer does not noticeably segregates around nickel coated diamondparticles and the fillet connecting diamond particles to the wire issmall. The abrasive article has a tacking factor (t_(fl)/t_(f)) of about1, a fillet-to-particle factor (t_(f)/d_(ab)) of about 0.11, afillet-to-bonding layer factor (t_(f)/t_(bl)) of 0.5, a contact factor(A_(b)/A_(f)) of more than 5.

A 4 inch C-Plane sapphire workpiece was provided for conducting acutting operation. The workpiece was sliced to form 4 wafers using afirst sample (S1) representative of an abrasive article of Example 1.Additionally, the workpiece was slice to form 4 wafers using a secondsample (S2) representative of an abrasive article of Example 2. Theworkpiece was sliced under the conditions indicated below in Table 1below.

TABLE 1 Input & Testing Conditions Machine Takatori K2 Ingot Material &Size 4″ Sapphire, C-Plane # of wafers 4 Wire speed (m/min) 400 WireTension (N) 30 Wire usage (M) 140 Wire guide pitch (mm) 1 Rocking angle(degrees) 5 Rocking speed (degrees/min) 500 Time of Cut (hrs:mins) 10:02

After completing the cutting operation, the quality of the wafers formedfrom the workpiece was evaluated. The evaluation included a generalmeasure of damage to the wafer by the slicing operation includinganalysis of total thickness variation (TTV) and surface roughness (Ra)of each of the wafers. As illustrated in Table 2 below, the wafersformed by sample S2 for the sapphire had a thickness variation that wasapproximately 50% lower (i.e., 50% improvement) than the thicknessvariation of Sample S1 with comparable Ra. The data demonstrates aremarkable improvement in the quality of wafers formed using sample S2over sample S1.

TABLE 2 Characteristic Sample S1 Sample S2 TTV 28 ± 1  19 ± 2  Ra 0.42 ±0.05 0.38 ± 0.04

The present application represents a departure from the state of theart. Notably, the embodiments herein demonstrate improved and unexpectedperformance over conventional wire saws. While not wishing to be boundto a particular theory, it is suggested that combination of certainfeatures including designs, processes, materials, and the like mayfacilitate such improvements. The combination of features can include,but is not limited to, controlled processing conditions includingre-flow temperature, filler content, filler size, filler composition,average particle size of the abrasive particles, size distribution ofthe abrasive particles, content of the abrasive particles, compositionof the abrasive particles, thickness of the first layer, composition ofthe first layer, atmospheric conditions, and a combination thereof, andfillet characteristics including a tacking factor (t_(fl)/t_(f)), afillet-to-particle factor (t_(f)/d_(ab)), a fillet-to-bonding layerfactor (t_(f)/t_(bl)), a contact factor (A_(b)/A_(f)) or a fillet sizevariance (V_(f)). The combination of features can also include, but isnot limited to, fillet characteristics including a tacking factor(t_(fl)/t_(f)) of not greater than about 2, a fillet-to-particle factor(t_(f)/d_(ab)) of not greater than about 1, a fillet-to-bonding layerfactor (t_(f)/t_(bl)) of not greater than about 1, a contact factor(A_(b)/A_(f)) of at least about 1 or a combination thereof. Notably, theindustry has generally tried to reduce the thickness of underlyinglayers to reduce the size of fillets. However, quite unexpectedly, andcontrary to some conventional approaches, the inventors of the presentapplication have found that certain controlled processing conditions maybe utilized to facilitate certain desired fillet characteristics, whichmay in turn facilitate improved performance in certain abrasiveapplications. Notably, despite an expectation that larger fillets mayfacilitate improved holding of abrasive particles, it was surprisingfound that fillets of certain characteristics can provide improvedperformance on harder materials. Moreover, without wishing to be tied toa particular theory, it has been offered that certain other filletcharacteristics can be tailored to other abrasive applications, and suchfillet characteristics can have remarkable affects on the grindingperformance of an abrasive article depending upon the intended abrasiveapplication.

The above-disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments, which fall withinthe true scope of the present invention. Thus, to the maximum extentallowed by law, the scope of the present invention is to be determinedby the broadest permissible interpretation of the following claims andtheir equivalents, and shall not be restricted or limited by theforegoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law andis submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. In addition, inthe foregoing Detailed Description of the Drawings, various features maybe grouped together or described in a single embodiment for the purposeof streamlining the disclosure. This disclosure is not to be interpretedas reflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may be directed toless than all features of any of the disclosed embodiments. Thus, thefollowing claims are incorporated into the Detailed Description of theDrawings, with each claim standing on its own as defining separatelyclaimed subject matter.

Item 1. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; a bonding layer overlying the abrasiveparticles; and wherein the fillets have a fillet characteristic relativeto an abrasive application, the fillet characteristic selected from thegroup consisting of a tacking factor (tfl/tf), a fillet-to-particlefactor (tf/dab), a fillet-to-bonding layer factor (tf/tbl), a contactfactor (Ab/Af), a fillet size variance (Vf), and a combination thereof.

Item 2. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; a bonding layer overlying the abrasiveparticles; and wherein the fillets have a fillet characteristic adaptedto an abrasive application, the fillet characteristic selected from thegroup consisting of a tacking factor (tfl/tf), a fillet-to-particlefactor (tf/dab), a fillet-to-bonding layer factor (tf/tbl), a contactfactor (Ab/Af), a fillet size variance (Vf), and a combination thereof.

Item 3. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; and a fillet characteristic comprising afillet-to-particle factor (tf/dab) for an abrasive application of theabrasive article, wherein tf represents an average maximum thickness ofthe fillets and dab represents a median particle size of the abrasiveparticles.

Item 4. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; and a fillet characteristic comprising atacking factor (tfl/tf) for an abrasive application of the abrasivearticle, wherein to represents an average thickness of the first layerand tf represents an average maximum thickness of the fillets.

Item 5. A method of forming an abrasive article comprising: providing abody including abrasive particles overlying a first layer, the firstlayer overlying a substrate; processing at least the substrate, thefirst layer, and the abrasive particles according to a controlledprocessing condition to form an abrasive article having a filletcharacteristic relative to an abrasive application, the filletcharacteristic selected from the group consisting of a tacking factor(tfl/tf), a fillet-to-particle factor (tf/dab), a fillet-to-bondinglayer factor (tf/tbl), a contact factor (Ab/Af), a fillet size variance(Vf), and a combination thereof; and wherein the controlled processingcondition is selected from the group consisting of re-flow temperature,filler content, filler size, filler composition, average particle sizeof the abrasive particles, size distribution of the abrasive particles,content of the abrasive particles, composition of the abrasiveparticles, thickness of the first layer, composition of the first layer,atmospheric conditions, and a combination thereof.

Item 6. The abrasive article and method of any one of items 1, 2, 4, and5, wherein the tacking factor (tfl/tf) is at least about 0.01, at leastabout 0.02, at least about 0.03, at least about 0.04, at least about0.05, at least about 0.1, at least about 0.2, at least about 0.3, atleast about 0.4, at least about 0.5, at least about 0.6, at least about0.7, at least about 0.8, at least about 0.9, at least about 1.0, atleast about 1.1, at least about 1.2, at least about 1.3, at least about1.4, at least about 1.5, at least about 1.6, at least about 1.7, atleast about 1.8 and at least about 1.9; and wherein tfl represents anaverage thickness of the first layer and tf represents an averagemaximum thickness of the fillets.

Item 7. The abrasive article and method of any one of items 1, 2, 4, and5, wherein the tacking factor (tfl/tf) is not greater than about 2, notgreater than about 1.9, not greater than about 1.8, not greater thanabout 1.7, not greater than about 1.6, not greater than about 1.5, notgreater than about 1.4, not greater than about 1.3, not greater thanabout 1.2, not greater than about 1.1, not greater than about 1, notgreater than about 0.9, not greater than about 0.8, not greater thanabout 0.7, not greater than about 0.6, not greater than about 0.5, notgreater than about 0.4, not greater than about 0.3 and not greater thanabout 0.2, wherein tfl represents an average thickness of the firstlayer and tf represents an average maximum thickness of the fillets.

Item 8. The abrasive article of item 3, further comprising a filletcharacteristic comprising a tacking factor (tfl/tf), wherein the tackingfactor (tfl/tf) is at least about 0.01, at least about 0.02, at leastabout 0.03, at least about 0.04, at least about 0.05, at least about0.1, at least about 0.2, at least about 0.3, at least about 0.4, atleast about 0.5, at least about 0.6, at least about 0.7, at least about0.8, at least about 0.9, at least about 1.0, at least about 1.1, atleast about 1.2, at least about 1.3, at least about 1.4, at least about1.5, at least about 1.6, at least about 1.7, at least about 1.8 and atleast about 1.9; and wherein tfl represents an average thickness of thefirst layer and tf represents an average maximum thickness of thefillets.

Item 9. The abrasive article of item 3, further comprising a filletcharacteristic comprising a tacking factor (tfl/tf), wherein the tackingfactor (tfl/tf) is not greater than about 2, not greater than about 1.9,not greater than about 1.8, not greater than about 1.7, not greater thanabout 1.6, not greater than about 1.5, not greater than about 1.4, notgreater than about 1.3, not greater than about 1.2, not greater thanabout 1.1, not greater than about 1, not greater than about 0.9, notgreater than about 0.8, not greater than about 0.7, not greater thanabout 0.6, not greater than about 0.5, not greater than about 0.4, notgreater than about 0.3 and not greater than about 0.2, wherein tflrepresents an average thickness of the first layer and tf represents anaverage maximum thickness of the fillets.

Item 10. The abrasive article and method of any one of items 1, 2, 3,and 5, wherein the fillet characteristic of the fillet-to-particlefactor (tf/dab) is at least about 0.01, at least about 0.02, at leastabout 0.03, at least about 0.04, at least about 0.05, at least about0.06, at least about, at least about 0.08, at least about 0.1, at leastabout 0.12, at least about 0.15, at least about 0.2, at least about0.25, at least about 0.3, at least about 0.35, at least about 0.4, atleast about 0.45, at least about 0.5 and at least about 0.5.

Item 11. The abrasive article of item 4, further comprising a filletcharacteristic comprising a fillet-to-particle factor (tf/dab), whereinthe fillet characteristic of the fillet-to-particle factor (tf/dab) isat least about 0.01, at least about 0.02, at least about 0.03, at leastabout 0.04, at least about 0.05, at least about 0.06, at least about, atleast about 0.08, at least about 0.1, at least about 0.12, at leastabout 0.15, at least about 0.2, at least about 0.25, at least about 0.3,at least about 0.35, at least about 0.4, at least about 0.45, at leastabout 0.5 and at least about 0.5.

Item 12. The abrasive article and method of any one of items 1, 2, 3,and 5, wherein the fillet characteristic of the fillet-to-particlefactor (tf/dab) is not greater than about 0.95, not greater than about0.9, not greater than about 0.85, not greater than about 0.80, notgreater than about 0.75, not greater than about 0.7, not greater thanabout 0.7, not greater than about 0.65 and greater than about 0.6.

Item 13. The abrasive article of item 4, further comprising a filletcharacteristic comprising a fillet-to-particle factor (tf/dab), whereinthe fillet characteristic of the fillet-to-particle factor (tf/dab)wherein the fillet characteristic of the fillet-to-particle factor(tf/dab) is not greater than about 0.95, not greater than about 0.9, notgreater than about 0.85, not greater than about 0.80, not greater thanabout 0.75, not greater than about 0.7, not greater than about 0.7, notgreater than about 0.65 and greater than about 0.6.

Item 14. The abrasive article and method of any one of items 1, 2, and5, wherein the contact factor (Ab/Af) is not greater than about 100, notgreater than about 95, not greater than about 90, not greater than about85, not greater than about 80, not greater than about 75, not greaterthan about 70, not greater than about 65, not greater than about 60, notgreater than about 55, not greater than about 50, not greater than about45, not greater than about 40, not greater than about 35, not greaterthan about 30, not greater than about 25, not greater than about 20, notgreater than about 15 and not greater than about 10, wherein Abrepresents an average percentage of a surface area of the abrasiveparticles in contact with the bonding layer, and Af represents anaverage percentage of the surface area of the abrasive particles incontact with the fillets.

Item 15. The abrasive article of any one of items 3 and 4, furthercomprising a fillet characteristic comprising a contact factor (Ab/Af),wherein the contact factor (Ab/Af) is not greater than about 100, notgreater than about 95, not greater than about 90, not greater than about85, not greater than about 80, not greater than about 75, not greaterthan about 70, not greater than about 65, not greater than about 60, notgreater than about 55, not greater than about 50, not greater than about45, not greater than about 40, not greater than about 35, not greaterthan about 30, not greater than about 25, not greater than about 20, notgreater than about 15 and not greater than about 10, wherein Abrepresents an average percentage of a surface area of the abrasiveparticles in contact with the bonding layer, and Af represents anaverage percentage of the surface area of the abrasive particles incontact with the fillets.

Item 16. The abrasive article and method of any one of items 1, 2, and5, wherein the contact factor (Ab/Af) is at least about 0.01, at leastabout 0.02, at least about 0.05, at least about 0.08, at least about0.1, at least about 0.15, at least about 0.2, at least about 0.25, atleast about 0.3, at least about 0.35, at least about 0.4, at least about0.45, at least about 0.5, at least about 0.55, at least about 0.6, atleast about 0.65, at least about 0.7, at least about 0.75, at leastabout 0.8, at least about 0.85, at least about 0.9 and at least about0.95, wherein Ab represents an average percentage of a surface area ofthe abrasive particles in contact with the bonding layer, and Afrepresents an average percentage of the surface area of the abrasiveparticles in contact with the fillets.

Item 17. The abrasive article of any one of items 3 and 4, furthercomprising a fillet characteristic comprising a contact factor (Ab/Af),wherein the contact factor (Ab/Af) is at least about 0.01, at leastabout 0.02, at least about 0.05, at least about 0.08, at least about0.1, at least about 0.15, at least about 0.2, at least about 0.25, atleast about 0.3, at least about 0.35, at least about 0.4, at least about0.45, at least about 0.5, at least about 0.55, at least about 0.6, atleast about 0.65, at least about 0.7, at least about 0.75, at leastabout 0.8, at least about 0.85, at least about 0.9 and at least about0.95, wherein Ab represents an average percentage of a surface area ofthe abrasive particles in contact with the bonding layer, and Afrepresents an average percentage of the surface area of the abrasiveparticles in contact with the fillets.

Item 18. The abrasive article and method of any one of items 1, 2, and5, wherein the fillet-to-bonding layer factor (tf/tbl) is at least about0.01, at least about 0.02, at least about 0.05, at least about 0.1, atleast about 0.15, at least about 0.2, at least about 0.25, at leastabout 0.3, at least about 0.35, at least about 0.4, at least about 0.45and at least about 0.5, wherein tbl represents an average thickness ofthe bonding layer and tf represents an average maximum thickness of thefillets.

Item 19. The abrasive article of any one of items 3 and 4, furthercomprising a fillet characteristic comprising a fillet-to-bonding layerfactor (tf/tbl), wherein the fillet-to-bonding layer factor (tf/tbl) isat least about 0.01, at least about 0.02, at least about 0.05, at leastabout 0.1, at least about 0.15, at least about 0.2, at least about 0.25,at least about 0.3, at least about 0.35, at least about 0.4, at leastabout 0.45 and at least about 0.5, wherein tbl represents an averagethickness of the bonding layer and tf represents an average maximumthickness of the fillets.

Item 20. The abrasive article and method of any one of items 1, 2, and5, wherein the fillet-to-bonding layer factor (tf/tbl) is not greaterthan about 100 not greater than about 80, not greater than about 60, notgreater than about 40, not greater than about 20, not greater than about10, not greater than about 5, not greater than about 4, not greater thanabout 3.5, not greater than about 3, not greater than about 2.8, notgreater than about 2.6, not greater than about 2.4, not greater thanabout 2.2, not greater than about 2, not greater than about 1.9, notgreater than about 1.8, not greater than about 1.7, not greater thanabout 1.6, not greater than about 1.5, not greater than about 1.4, notgreater than about 1.3, not greater than about 1.2 and not greater thanabout 1.1, wherein tbl represents an average thickness of the bondinglayer and tf represents an average maximum thickness of the fillets.

Item 21. The abrasive article of any one of items 3 and 4, furthercomprising a fillet characteristic comprising a fillet-to-bonding layerfactor (tf/tbl), wherein the fillet-to-bonding layer factor (tf/tbl) isnot greater than about 100 not greater than about 80, not greater thanabout 60, not greater than about 40, not greater than about 20, notgreater than about 10, not greater than about 5, not greater than about4, not greater than about 3.5, not greater than about 3, not greaterthan about 2.8, not greater than about 2.6, not greater than about 2.4,not greater than about 2.2, not greater than about 2, not greater thanabout 1.9, not greater than about 1.8, not greater than about 1.7, notgreater than about 1.6, not greater than about 1.5, not greater thanabout 1.4, not greater than about 1.3, not greater than about 1.2 andnot greater than about 1.1, wherein tbl represents an average thicknessof the bonding layer and tf represents an average maximum thickness ofthe fillets.

Item 22. The abrasive article and method of any one of items 1, 2, and5, wherein the fillet size variance (Vf) is not greater than about 95%,not greater than about 93%, not greater than about 90%, not greater thanabout 88%, not greater than about 85%, not greater than about 83%, notgreater than about 80%, not greater than about 78%, not greater thanabout 75%, not greater than about 73%, not greater than about 70%, notgreater than about 68%, not greater than about 65%, not greater thanabout 63%, not greater than about 60%, not greater than about 58%, notgreater than about 55%, not greater than about 53%, not greater thanabout 50%, not greater than about 48%, not greater than about 45%, notgreater than about 43%, not greater than about 40%, not greater thanabout 30%, not greater than about 20% and not greater than about 10%based on the equation [(Fmax−tf/Fmax]×100%, wherein Fmax represents agreatest value of fillet thickness of a sample and tf represents theaverage maximum thickness of the fillets of a sample.

Item 23. The abrasive article of any one of items 3 and 4, furthercomprising a fillet characteristic comprising a fillet size variance(VI), wherein the fillet size variance (VI) is not greater than about95%, not greater than about 93%, not greater than about 90%, not greaterthan about 88%, not greater than about 85%, not greater than about 83%,not greater than about 80%, not greater than about 78%, not greater thanabout 75%, not greater than about 73%, not greater than about 70%, notgreater than about 68%, not greater than about 65%, not greater thanabout 63%, not greater than about 60%, not greater than about 58%, notgreater than about 55%, not greater than about 53%, not greater thanabout 50%, not greater than about 48%, not greater than about 45%, notgreater than about 43%, not greater than about 40%, not greater thanabout 30%, not greater than about 20% and not greater than about 10%based on the equation [(Fmax−tf)/Fmax]×100%, wherein Fmax represents agreatest value of fillet thickness of a sample and tf represents theaverage maximum thickness of the fillets of a sample.

Item 24. The abrasive article and method of any one of items 1, 2, and5, wherein the fillet size variance (Vf) is at least about 2%, at leastabout 5%, at least about 10%, at least about 20%, at least about 30%, atleast about 40% and at least about 50% based on the equation[(Fmax−tf/Fmax]×100%, wherein Fmax represents a greatest value of filletthickness of a sample and tf represents the average maximum thickness ofthe fillets of a sample.

Item 25. The abrasive article of any one of items 3 and 4, furthercomprising a fillet characteristic comprising a fillet size variance(Vf), wherein the fillet size variance (Vf) is at least about 2%, atleast about 5%, at least about 10%, at least about 20%, at least about30%, at least about 40% and at least about 50% based on the equation[(Fmax−tf)/Fmax]×100%, wherein Fmax represents a greatest value offillet thickness of a sample and tf represents the average maximumthickness of the fillets of a sample.

Item 26. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the fillets comprise a composition that is substantiallythe same as a composition of the first layer, wherein the fillets have acomposition that is essentially the same as a composition of the firstlayer, wherein the fillets comprise a composition having a difference inelemental composition of not greater than about 5 mol % for any elementcompared to a composition of the first layer.

Item 27. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the fillets have a composition that is substantiallydifferent compared to a composition of the first layer, wherein thefillets have a composition that includes at least one element differentthan an element of the first layer, wherein the fillets have acomposition having a difference in elemental composition of at leastabout 5 mol % for any element compared to a composition of the firstlayer.

Item 28. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the fillets comprise an active bonding material, whereinthe active bonding material comprises a material selected from the groupconsisting of borides, oxides, nitrides, carbides, oxynitrides,oxyborides, oxycarbides, and a combination thereof, wherein the filletscomprise titanium, wherein the fillets comprise titanium carbide.

Item 29. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the fillets comprise a metal, wherein the filletscomprise a metal alloy, wherein the fillets comprise an elemental metal,wherein the fillets comprise a transition metal element, wherein thefillets comprise tin, wherein the fillets comprise copper, wherein thefillets comprise nickel, wherein the fillets comprise solder, whereinthe fillets comprise a mixture of tin and copper.

Item 30. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the fillets comprise a mixture of a composition of thefirst layer and an active bonding material, wherein the fillets compriseat least two discrete phases of material including a first phase and asecond phase, wherein the first phase is preferentially located closerto a surface of the abrasive particles as compared to the second phase,wherein the fillets comprises at least three discrete phases of materialincluding a first phase, a second phase, and a third phase.

Item 31. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the fillets extend from the first layer, wherein thefillets are integral with the first layer, wherein the fillets form anamalgamate with the first layer.

Item 32. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, further comprising a combination of at least two filletcharacteristics from the group consisting of tacking factor (tfl/tf), afillet-to-particle factor (tf/dab), a fillet-to-bonding layer factor(tf/tbl), a contact factor (Ab/Af), a fillet size variance (Vf).

Item 33. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the abrasive application is based upon at least oneparameter selected from the group consisting of a workpiece hardness, aworkpiece size, a workpiece composition, abrasive article life, abrasiveparticle retention strength, cutting force and workpiece quality.

Item 34. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, further comprising a filler in the first layer distinct from theabrasive particles, wherein the filler is distinct from the abrasiveparticles based on at least one filler criteria selected from the groupconsisting of average particle size, composition, content,concentration, distribution, and a combination thereof.

Item 35. The abrasive article and method of item 34, wherein theabrasive particles comprises an average particle size (P1) and thefiller comprises a filler average particle size (F1), and wherein theaverage particle size is greater than the filler average particle size,wherein the average particle size is at least about 5% different thanthe filler average particle size based on the equation((P1−F1)/P1)×100%, at least about 10% different, at least about 20%different, at least about 30% different, and not greater than about 99%different.

Item 36. The abrasive article and method of item 34, wherein the fillercomprises an average particle size of not greater than about 500microns, not greater than about 300 microns, not greater than about 200microns, not greater than about 150 microns, not greater than about 100microns, not greater than about 80 microns, not greater than about 50microns, not greater than about 30 microns, not greater than about 20microns, not greater than about 15 microns, not greater than about 12microns, not greater than about 10 microns, not greater than about 8microns, and wherein the filler comprises an average particle size of atleast about 0.01 microns.

Item 37. The abrasive article and method of item 34, wherein the fillercomprises a material selected from the group consisting of an inorganicmaterial, an organic material, a polymer, a synthetic material, anatural material, and a combination thereof, wherein the fillercomprises a material selected from the group consisting of athermoplastic, a thermoset, a resin, a ceramic, a glass, a metal, ametal alloy, a metal coated particle, a substantially spherical bead, ahollow body, an elongated body, a fiber, and a combination thereof,wherein the filler comprises a material selected from the groupconsisting of an oxide, a carbide, a nitride, a boride, diamond, acarbon-based material, cubic boron nitride, and a combination thereof,wherein the filler comprises a Vickers hardness of at least about 0.1GPa, at least about 1 GPa, such as at least about 3 GPa, wherein thefiller comprises a Vickers hardness not greater than about 200 GPa, notgreater than about 150 GPa, not greater than about 100 GPa.

Item 38. The abrasive article and method of item 34, wherein theabrasive particles comprise an average hardness (Hap) and the fillercomprises a filler average hardness (Hf), and wherein the averagehardness (Hap) is greater than the filler average hardness (Hf), whereinthe average hardness is at least about 5% different than the filleraverage hardness based on the equation ((Hap−Hf)/Hap)×100%, at leastabout 10% different, at least about 20% different, at least about 30%different, and not greater than about 99% different.

Item 39. The abrasive article and method of item 34, wherein the fillercomprises a filler composition distinct from an abrasive particlecomposition, wherein the filler composition is different from theabrasive particle composition by at least 5 wt % of at least one elementwithin the filler composition and the abrasive particle composition.

Item 40. The abrasive article and method of item 34, wherein theabrasive particles are present in an abrasive particle content and thefiller is present in a filler content, wherein the abrasive articleincludes an abrasive particle content greater than a filler content,wherein the filler content is greater than the abrasive particlecontent, wherein the abrasive particle content is substantially the sameas the filler content, further comprising a particle count ratio(Cap:Cf) of abrasive particle content (Cap) to filler content (Cf) ofnot greater than about 100:1, not greater than about 50:1, not greaterthan about 20:1, not greater than about 10:1, not greater than about5:1, not greater than about 2:1, and approximately 1:1, and wherein theparticle count ratio (Cap:Cf) is at least about 2:1, at least about 5:1,at least about 10:1, at least about 20:1, at least about 50:1, at leastabout 100:1.

Item 41. The abrasive article and method of item 34, wherein the fillerhas a greater wetting affinity for a composition of the first layer ascompared to a wetting affinity of the abrasive particles relative to thecomposition of the first layer.

Item 42. The method of item 5, wherein processing according to thecontrolled processing condition includes heating the substrate, thefirst layer, and the abrasive particles to a re-flow temperature,wherein heating comprises selecting a re-flow temperature and aviscosity and controlling the wetting of the first layer on the abrasiveparticles, wherein heating comprises selecting a re-flow temperaturecorresponding to a predetermined viscosity to control the wetting of thefirst layer on the abrasive particles and controlling the averagemaximum thickness of the fillets.

Item 43. The method of item 42, wherein the re-flow temperature is lessthan a melting temperature of the first layer, wherein the re-flowtemperature is different than the melting temperature by at least about0.5% based on the equation [(Tm−Tr)/Tm]×100%, wherein Tm represents themelting temperature and Tr represents the re-flow temperature, whereinthe re-flow temperature is different than the melting temperature by atleast about 1%, at least about 2%, at least about 3%, at least about 4%,at least about 5%, at least about 8%, at least about 10%, at least about12%, at least about 15%, at least about 20%, at least about 30%, atleast about 40%.

Item 44. The method of item 5, wherein processing according to thecontrolled processing condition includes changing a viscosity of thefirst layer and controlling the wetting of the abrasive particles by thefirst layer, wherein processing according to the controlled processingcondition includes increasing a viscosity of the first layer andcontrolling the amount of wetting of the abrasive particles by the firstlayer.

Item 45. The method of item 5, wherein processing according to thecontrolled processing condition includes providing a filler to controlthe wetting of the first layer on the abrasive particles, whereinprocessing according to the controlled processing condition comprisesselecting at least one of a filler composition, a filler size, and afiller content to control the wetting of the first layer on the abrasiveparticles, wherein processing according to the controlled processingcondition includes providing a filler to control the average maximumthickness of the fillets.

Item 46. The method of item 5, wherein processing according to thecontrolled processing condition includes providing an atmosphericcondition selected from the group consisting of a reducing atmosphere,an oxidizing atmosphere, an inert atmosphere, an atmosphere consistingessentially of one element, and a combination thereof.

Item 47. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the substrate comprises a material selected from thegroup consisting of metal, metal alloys, ceramic, glass, and acombination thereof, wherein the substrate comprises a metal comprisinga transition metal element, wherein the substrate comprises steel,wherein the substrate has an elongated body, the substrate comprises anelongated body having an aspect ratio of length:width of at least about10:1, wherein the substrate comprises an elongated body having an aspectratio of length:width of at least about 10000:1.

Item 48. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the substrate comprises an average length of at leastabout 50 m, at least about 100 m, at least about 500 m, at least about1000 m, wherein the substrate comprises an average width of not greaterthan about 1 mm, not greater than about 0.8 mm, not greater than about0.5 mm, wherein the core of the substrate comprises an average width ofat least about 0.01 mm, wherein the substrate consists essentially of awire, wherein the core of the substrate comprises a plurality offilaments braided together.

Item 49. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, further comprising a barrier layer in direct contact with aperipheral surface of the substrate, wherein the barrier layer isdisposed between the peripheral surface of the substrate and the firstlayer, wherein the barrier layer comprises an inorganic material,wherein the barrier layer comprises a metal or metal alloy, wherein thebarrier layer comprises a transition metal element, wherein the barrierlayer comprises a material different from the first layer, where in thebarrier layer consists of copper, wherein the barrier layer consistsessentially of nickel, wherein the barrier layer comprises a non-alloyedmaterial.

Item 50. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the first layer is configured to be a tacking layer andprovisionally hold the abrasive particles in place during processing,wherein the first layer is in direct contact with a surface of thesubstrate.

Item 51. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the first layer comprises a material selected from thegroup of materials consisting of metal, metal alloys, metal matrixcomposites, and a combination thereof, wherein the first layer comprisesa transition metal element, wherein the first layer comprises an alloyof transition metal elements, wherein the first layer comprises tin,wherein the first layer comprises a metal selected from the group ofmetals consisting of lead, silver, copper, zinc, tin, indium, titanium,molybdenum, chromium, iron, manganese, cobalt, niobium, tantalum,tungsten, palladium, platinum, gold, ruthenium, and a combinationthereof, wherein the first layer comprises a metal alloy of tin andlead, wherein the first layer comprises tin, wherein the first layerconsists essentially of tin.

Item 52. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the first layer comprises a solder material, wherein thefirst layer has a melting point of not greater than about 450° C., notgreater than about 400° C., not greater than about 375° C., not greaterthan about 350° C., and at least about 100° C.

Item 53. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the first layer comprises an average thickness of notgreater than about 80% of an average particle size of the abrasiveparticles, not greater than about 70%, not greater than about 40%, andwherein the first layer comprises an average thickness of at least about2%, at least about 5%, at least about 6%, at least about 7%, at leastabout 8%, at least about 9%, at least about 10%, at least about 11%, atleast about 12%, at least about 13%.

Item 54. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the abrasive particles comprises a material selected fromthe group of materials consisting of oxides, carbides, nitrides,borides, oxynitrides, oxyborides, diamond, and a combination thereof,wherein the abrasive particles comprises a superabrasive material,wherein the abrasive particles comprises diamond, the abrasive particlesconsists essentially of diamond, wherein the abrasive particlescomprises a material having a Vickers hardness of at least about 10 GPa.

Item 55. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, wherein the abrasive particles include a first type of abrasiveparticle and a second type of abrasive particle different than the firsttype of abrasive particle, wherein the first type of abrasive particleis different than the second type of abrasive particle based on at leastone particle characteristics selected from the group consisting ofhardness, friability, toughness, particle shape, crystalline structure,average particle size, composition, particle coating, grit sizedistribution, and a combination thereof.

Item 56. The abrasive article and method of item 55, wherein the firsttype of abrasive particle comprises a first average particle size (P1)and the second type of abrasive particle comprises a second averageparticle size (P2), and wherein the first average particle size isgreater than the second average particle size, wherein the first averageparticle size is at least about 5% different than the second averageparticle size based on the equation ((P1−P2)/P1)×100%, at least about10% different, at least about 20% different, at least about 30%different, and not greater than about 99% different.

Item 57. The abrasive article of any one of items 1 and 2, wherein thebonding layer directly contacts at least a portion of the first layer,wherein the bonding layer directly contacts a portion of the abrasiveparticles, wherein the bonding layer directly contacts a particle filmlayer on the abrasive particles, wherein the bonding layer overlies amajority of an external surface of the substrate and an external surfaceof the abrasive particles.

Item 58. The abrasive article and method of any one of items 3, 4, and5, further comprising a bonding layer overlying the abrasive particles,wherein the bonding layer directly contacts at least a portion of thefirst layer, wherein the bonding layer directly contacts a portion ofthe abrasive particles, wherein the bonding layer directly contacts aparticle film layer on the abrasive particles, wherein the bonding layeroverlies a majority of an external surface of the substrate and anexternal surface of the abrasive particles.

Item 59. The abrasive article and method of item 58, wherein the bondinglayer comprises a material selected from the group of materialsconsisting of metals, metal alloys, cements, ceramics, composites, and acombination thereof, wherein the bonding layer comprises a transitionmetal element, wherein the bonding layer comprises an alloy oftransition metal elements, wherein the bonding layer comprises a metalselected from the group of metals consisting of lead, silver, copper,zinc, tin, titanium, molybdenum, chromium, iron, manganese, cobalt,niobium, tantalum, tungsten, palladium, platinum, gold, ruthenium, and acombination thereof, wherein the bonding layer comprises nickel, whereinthe bonding layer consists essentially of nickel.

Item 60. The abrasive article and method of item 58, wherein the bondinglayer comprises an average thickness of at least about 5% of an averageparticle size of the abrasive particles, wherein the bonding layercomprises an average thickness of not greater than about 100% of anaverage particle size of the abrasive particles.

Item 61. The abrasive article and method of item 58, wherein the bondinglayer comprise an average thickness of at least about 1 micron, at leastabout 2 microns, at least about 3 microns, not greater than about 60microns, not greater than about 50 microns, not greater than about 40microns, not greater than about 30 microns.

Item 62. The abrasive article and method of any one of items 1 and 2,wherein the bonding layer comprises a material selected from the groupof materials consisting of metals, metal alloys, cements, ceramics,composites, and a combination thereof, wherein the bonding layercomprises a transition metal element, wherein the bonding layercomprises an alloy of transition metal elements, wherein the bondinglayer comprises a metal selected from the group of metals consisting oflead, silver, copper, zinc, tin, titanium, molybdenum, chromium, iron,manganese, cobalt, niobium, tantalum, tungsten, palladium, platinum,gold, ruthenium, and a combination thereof, wherein the bonding layercomprises nickel, wherein the bonding layer consists essentially ofnickel.

Item 63. The abrasive article and method of any one of items 1 and 2,wherein the bonding layer comprises an average thickness of at leastabout 5% of an average particle size of the abrasive particles, whereinthe bonding layer comprises an average thickness of not greater thanabout 100% of an average particle size of the abrasive particles.

Item 64. The abrasive article and method of any one of items 1 and 2,wherein the bonding layer comprise an average thickness of at leastabout 1 micron, at least about 2 microns, at least about 3 microns, notgreater than about Item 60 microns, not greater than about 50 microns,not greater than about 40 microns, not greater than about 30 microns.

Item 65. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, further comprising a coating layer overlying the substrate,wherein the coating layer overlies the bonding layer, wherein thecoating layer comprises a material selected from the group of materialsconsisting of metals, metal alloys, cements, ceramics, organics and acombination thereof.

Item 66. The abrasive article and method of any one of items 1, 2, 3, 4,and 5, further comprising an abrasive particle concentration of theabrasive particles particle of at least about 5 particles per mm ofsubstrate, at least about 7 particles per mm of substrate, at leastabout 10 particles per mm of substrate, at least about 20 particles permm of substrate, at least about 30 particles per mm of substrate, andnot greater than about 800 particles per mm of substrate.

Item 67. The method of item 5, wherein providing a body comprises:providing a substrate; forming the first layer using a depositionprocess selected from the group consisting of spraying, gravity coating,dipping, die coating, electrostatic coating, and a combination thereof;placing the abrasive particles on the first layer in contact with thefirst layer to bind the first type of abrasive particle to the firstlayer, wherein placing the first type of abrasive particle on the firstlayer comprises a deposition process selected from the group consistingof spraying, gravity coating, dipping, die coating, electrostaticcoating, and a combination thereof; wherein placing the abrasiveparticles on the first layer includes placing an additional layercomprising a flux material overlying the first layer; and furthercomprising heating the first layer to a temperature of not greater thanabout 450° C.

Item 68. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; and a tacking factor (t_(fl)/t_(f)) of notgreater than about 1.5, wherein t_(fl) represents an average thicknessof the first layer and t_(f) represents an average thickness of thefillets.

Item 69. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; and a fillet-to-particle factor(t_(f)/d_(ab)) of not greater than about 0.33, wherein t_(f) representsan average thickness of the fillets and d_(ab) represents an averageparticle size of the abrasive particles.

An abrasive article comprising: a substrate comprising an elongatedmember; a first layer overlying the substrate; abrasive particlesoverlying the first layer; fillets connecting the first layer and theabrasive particles; and a bonding layer overlying the abrasiveparticles, wherein a majority of the abrasive particles have an undercutregion defining a portion of the bonding layer extending under a portionof the abrasive particle between the abrasive particle and the firstlayer.

Item 71. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; a bonding layer overlying the abrasiveparticles; and wherein the abrasive particles have a contact factor(A_(b)/A_(f)) of at least about 1, wherein A_(b) represents an averagepercentage of a surface area of the abrasive particles in contact withthe bonding layer, and A_(f) represents an average percentage of thesurface area of the abrasive particles in content with the fillets.

Item 72. An abrasive article comprising: a substrate comprising anelongated member; a first layer overlying the substrate; abrasiveparticles overlying the first layer; fillets connecting the first layerand the abrasive particles; a bonding layer overlying the abrasiveparticles; at least one fillet characteristic selected from the groupconsisting of a tacking factor (t_(fl)/t_(f)) of not greater than about1.5, a fillet-to-particle factor (t_(f)/d_(ab)) of not greater thanabout 0.33, a fillet-to-bonding layer factor (t_(f)/t_(bl)) of notgreater than about 100, a contact factor (A_(b)/A_(f)) of at least about1, a fillet size variance (V_(f)) of not greater than 60% or acombination thereof; and wherein the first layer comprises an averagethickness of at least about 6% of an average particle size of theabrasive particles.

Item 73. A method of forming an abrasive article comprising: providing abody including abrasive particles overlying a first layer, the firstlayer overlying a substrate; processing at least the substrate, thefirst layer, and the abrasive particles according to a controlledprocessing condition to form an abrasive article having a filletcharacteristic selected from the group consisting of a tacking factor(t_(fl)/t_(f)) of not greater than about 1.5, a fillet-to-particlefactor (t_(f)/d_(ab)) of not greater than about 0.33, afillet-to-bonding layer factor (t_(f)/t_(bl)) of not greater than about100, a contact factor (A_(b)/A_(f)) of at least about 1, a fillet sizevariance (V_(f)) of not greater than 60% or a combination thereof; andwherein the controlled processing condition is selected from the groupconsisting of re-flow temperature, filler content, filler size, fillercomposition, average particle size of the abrasive particles, sizedistribution of the abrasive particles, content of the abrasiveparticles, composition of the abrasive particles, thickness of the firstlayer, composition of the first layer, and a combination thereof.

Item 74. The abrasive article and method of any one of items 68, 72, and73, wherein the tacking factor (t_(fl)/t_(f)) is not greater than about1.5, not greater than about 1.4, not greater than about 1.3, not greaterthan about 1.2, not greater than about 1.1, not greater than about 1,not greater than about 0.99, not greater than about 0.97, not greaterthan about 0.95, not greater than about 0.92, not greater than about0.9, not greater than about 0.85, not greater than about 0.8, notgreater than about 0.75, not greater than about 0.7, not greater thanabout 0.65, not greater than about 0.6, not greater than about 0.55 andnot greater than about 0.51.

Item 75. The abrasive article of any one of items 69, 70 and 71, furthercomprising a tacking factor (t_(fl)/t_(f)) of not greater than about1.5, not greater than about 1.4, not greater than about 1.3, not greaterthan about 1.2, not greater than about 1.1, not greater than about 1,not greater than about 0.99, not greater than about 0.97, not greaterthan about 0.95, not greater than about 0.92, not greater than about0.9, not greater than about 0.85, not greater than about 0.8, notgreater than about 0.75, not greater than about 0.7, not greater thanabout 0.65, not greater than about 0.6, not greater than about 0.55 andnot greater than about 0.51, wherein t_(fl) represents an averagethickness of the first layer and t_(f) represents an average maximumthickness of the fillets.

Item 76. The abrasive article and method of any one of items 68, 72, and73, wherein the tacking factor (t_(fl)/t_(f)) is at least about 0.5, atleast about 0.55, at least about 0.6, at least about 0.65, at leastabout 0.7, at least about 0.75, at least about 0.8, at least about 0.85,at least about 0.9, at least about 0.92, at least about 0.95, at leastabout 0.97, at least about 0.99, at least about 1, at least about 1.1,at least about 1.2, at least about 1.3 and at least about 1.4.

Item 77. The abrasive article of any one of items 69, 70 and 71, furthercomprising a tacking factor (t_(fl)/t_(f)) of at least about 0.5, atleast about 0.55, at least about 0.6, at least about 0.65, at leastabout 0.7, at least about 0.75, at least about 0.8, at least about 0.85,at least about 0.9, at least about 0.92, at least about 0.95, at leastabout 0.97, at least about 0.99, at least about 1, at least about 1.1,at least about 1.2, at least about 1.3 and at least about 1.4, whereint_(fl) represents an average thickness of the first layer and t_(f)represents an average maximum thickness of the fillets.

Item 78. The abrasive article and method of any one of items 69, 72 and73, wherein the fillet-to-particle factor (t_(f)/d_(ab)) is not greaterthan about 0.33, not greater than about 0.31, not greater than about0.3, not greater than about 0.27, not greater than about 0.25, notgreater than about 0.23, not greater than about 0.2, not greater thanabout 0.17, not greater than about 0.15, not greater than about 0.13,not greater than about 0.1, not greater than about 0.07 and not greaterthan about 0.06.

Item 79. The abrasive article of any one of items 68, 70 and 71, furthercomprising a fillet-to-particle factor (t_(f)/d_(ab)) of not greaterthan about 0.33, not greater than about 0.31, not greater than about0.3, not greater than about 0.27, not greater than about 0.25, notgreater than about 0.23, not greater than about 0.2, not greater thanabout 0.17, not greater than about 0.15, not greater than about 0.13,not greater than about 0.1, not greater than about 0.07 and not greaterthan about 0.06, wherein t_(f) represents an average maximum thicknessof the fillets and d_(ab) represents and an average particle size of theabrasive particles.

Item 80. The abrasive article and method of any one of items 69, 72 and73, wherein the fillet-to-particle factor (t_(f)/d_(ab)) is at leastabout 0.05, at least about 0.07, at least about 0.1, at least about0.12, at least about 0.14, at least about 0.16, at least about 0.18, atleast about 0.20, at least about 0.24, at least about 0.26, at leastabout 0.28, at least about 0.30 and at least about 0.32.

Item 81. The abrasive article of any one of items 68, 70 and 71, furthercomprising a fillet-to-particle factor (t_(f)/d_(ab)) of at least about0.05, at least about 0.07, at least about 0.1, at least about 0.12, atleast about 0.14, at least about 0.16, at least about 0.18, at leastabout 0.20, at least about 0.24, at least about 0.26, at least about0.28, at least about 0.30 and at least about 0.32, wherein t_(f)represents an average maximum thickness of the fillets and d_(ab)represents and an average particle size of the abrasive particles.

Item 82. The abrasive article and method of any one of items 72 and 73,wherein the fillet-to-bonding layer factor (t_(f)/t_(bl)) is not greaterthan about 100, not greater than about 90, not greater than about 80,not greater than about 70, not greater than about 60, not greater thanabout 50, not greater than about 40, not greater than about 35, notgreater than about 30, not greater than about 28, not greater than about26, not greater than about 24, not greater than about 22, not greaterthan about 20, not greater than about 18, not greater than about 16, notgreater than about 14, not greater than about 12 and not greater thanabout 11, wherein t_(f) represents an average maximum thickness of thefillets and t_(bl) represents and an average thickness of the bondinglayer.

Item 83. The abrasive article of any one of items 68, 69, 70 and 71,further comprising a fillet-to-bonding layer factor (t_(f)/t_(bl)) ofnot greater than about 100, not greater than about 90, not greater thanabout 80, not greater than about 70, not greater than about 60, notgreater than about 50, not greater than about 40, not greater than about35, not greater than about 30, not greater than about 28, not greaterthan about 26, not greater than about 24, not greater than about 22, notgreater than about 20, not greater than about 18, not greater than about16, not greater than about 14, not greater than about 12 and not greaterthan about 11, wherein t_(f) represents an average maximum thickness ofthe fillets and t_(bl) represents and an average thickness of thebonding layer.

Item 84. The abrasive article and method of any one of items 72 and 73,wherein the fillet-to-bonding layer factor (t_(f)/t_(bl)) is at leastabout 10, at least about 12, at least about 14, at least about 16, atleast about 18, at least about 20, at least about 22, at least about 24,at least about 26, at least about 28, at least about 30, at least about35, at least about 40, at least about 45, at least about 50, at leastabout 60, at least about 70, at least about 80, at least about 90 and atleast about 95, wherein t_(f) represents an average maximum thickness ofthe fillets and t_(bl) represents and an average thickness of thebonding layer.

Item 85. The abrasive article of any one of items 68, 69, 70 and 71,further comprising a fillet-to-bonding layer factor (t_(f)/t_(bl)) of atleast about 10, at least about 12, at least about 14, at least about 16,at least about 18, at least about 20, at least about 22, at least about24, at least about 26, at least about 28, at least about 30, at leastabout 35, at least about 40, at least about 45, at least about 50, atleast about 60, at least about 70, at least about 80, at least about 90and at least about 95, wherein t_(f) represents an average maximumthickness of the fillets and t_(bl) represents and an average thicknessof the bonding layer, wherein t_(f) represents an average maximumthickness of the fillets and t_(bl) represents and an average thicknessof the bonding layer.

Item 86. The abrasive article and method of any one of items 71, 72 and73, wherein the contact factor (A_(b)/A_(f)) is at least about 1.0, atleast about 1.2, at least about 1.4, at least about 1.5, at least about1.6, at least about 1.7, at least about 1.8, at least about 1.9, atleast about 2, at least about 2.2, at least about 2.4, at least about2.6, at least about 2.8, at least about 3, at least about 3.5, at leastabout 4, at least about 5, at least about 6, at least about 7, at leastabout 8 and at least about 9, wherein A_(b) represents an averagepercentage of a surface area of the abrasive particles in contact withthe bonding layer, and A_(f) represents an average percentage of thesurface area of the abrasive particles in contact with the fillets.

Item 87. The abrasive article of any one of items 68, 69 and 70, furthercomprising a contact factor (A_(b)/A_(f)) of at least about 1.0, atleast about 1.2, at least about 1.4, at least about 1.5, at least about1.6, at least about 1.7, at least about 1.8, at least about 1.9, atleast about 2, at least about 2.2, at least about 2.4, at least about2.6, at least about 2.8, at least about 3, at least about 3.5, at leastabout 4, at least about 5, at least about 6, at least about 7, at leastabout 8 and at least about 9, wherein A_(b) represents an averagepercentage of a surface area of the abrasive particles in contact withthe bonding layer, and A_(f) represents an average percentage of thesurface area of the abrasive particles in contact with the fillets.

Item 88. The abrasive article and method of any one of items 71, 72 and73, wherein the contact factor (A_(b)/A_(f)) is not greater than about10, not greater than about 9, not greater than about 8, not greater thanabout 7, not greater than about 6, not greater than about 5, not greaterthan about 4, not greater than about 3.5, not greater than about 3, notgreater than about 2.8, not greater than about 2.6, not greater thanabout 2.4, not greater than about 2.3, not greater than about 2.2, notgreater than about 2, not greater than about 1.9, not greater than about1.8, not greater than about 1.7, not greater than about 1.6, not greaterthan about 1.5, not greater than about 1.4, not greater than about 1.3,not greater than about 1.2 and not greater than about 1.1, wherein A_(b)represents an average percentage of a surface area of the abrasiveparticles in contact with the bonding layer, and A_(f) represents anaverage percentage of the surface area of the abrasive particles incontact with the fillets.

Item 89. The abrasive article of any one of items 68, 69 and 70, furthercomprising a contact factor (A_(b)/A_(f)) of not greater than about 10,not greater than about 9, not greater than about 8, not greater thanabout 7, not greater than about 6, not greater than about 5, not greaterthan about 4, not greater than about 3.5, not greater than about 3, notgreater than about 2.8, not greater than about 2.6, not greater thanabout 2.4, not greater than about 2.3, not greater than about 2.2, notgreater than about 2, not greater than about 1.9, not greater than about1.8, not greater than about 1.7, not greater than about 1.6, not greaterthan about 1.5, not greater than about 1.4, not greater than about 1.3,not greater than about 1.2 and not greater than about 1.1, wherein A_(b)represents an average percentage of a surface area of the abrasiveparticles in contact with the bonding layer, and A_(f) represents anaverage percentage of the surface area of the abrasive particles incontact with the fillets.

Item 90. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, further comprising a fillet size variance (V_(f)) of notgreater than about 60%, such as, not greater than about 58%, not greaterthan about 55%, not greater than about 53%, not greater than about 50%,not greater than about 48%, not greater than about 45%, not greater thanabout 43%, not greater than about 40%, not greater than about 30%, notgreater than about 20%, not greater than about 10%, not greater thanabout 8%, not greater than about 6%, not greater than about 4% or evennot greater than about 3%.

Item 91. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, further comprising a fillet size variance (V_(f)) of atleast about 2%, at least about 5%, at least about 10%, at least about20%, at least about 30%, at least about 40% or even at least about 50%.

Item 92. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein the fillets comprise a composition that issubstantially the same as a composition of the first layer, wherein thefillets have a composition that is essentially the same as a compositionof the first layer, wherein the fillets comprise a composition having adifference in elemental composition of not greater than about 5 wt. %for any element compared to a composition of the first layer.

Item 93. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein the fillets have a composition that issubstantially different compared to a composition of the first layer,wherein the fillets have a composition that includes at least oneelement different than an element of the first layer, wherein thefillets have a composition having a difference in elemental compositionof at least about 5 wt. % for any element compared to a composition ofthe first layer.

Item 94. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein the fillets comprise an active bonding material,wherein the active bonding material comprises a material selected fromthe group consisting of borides, oxides, nitrides, carbides,oxynitrides, oxyborides, oxycarbides, and a combination thereof, whereinthe fillets comprise titanium, wherein the fillets comprise titaniumcarbide.

Item 95. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein the fillets comprise a metal, wherein the filletscomprise a metal alloy, wherein the fillets comprise an elemental metal,wherein the fillets comprise a transition metal element, wherein thefillets comprise tin, wherein the fillets comprise copper, wherein thefillets comprise nickel, wherein the fillets comprise solder, whereinthe fillets comprise a mixture of tin and copper.

Item 96. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein the fillets comprise a mixture of a compositionof the first layer and an active bonding material, wherein the filletscomprise at least two discrete phases of material including a firstphase and a second phase, wherein the first phase is preferentiallylocated closer to a surface of the abrasive particles as compared to thesecond phase, wherein the fillets comprises at least three discretephases of material including a first phase, a second phase, and a thirdphase.

Item 97. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein the fillets extend from the first layer, whereinthe fillets are integral with the first layer, wherein the fillets forman amalgamate with the first layer.

Item 98. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, wherein further comprising a combination of at least twofillet characteristics from the group consisting of tacking factor(t_(fl)/t_(f)), a fillet-to-particle factor (t_(f)/d_(ab)), afillet-to-bonding layer factor (t_(f)/t_(bl)), and a contact factor(A_(b)/A_(f)).

Item 99. The abrasive article and method of any one of items 68, 69, 70,71, 72 and 73, further comprising a filler in the first layer distinctfrom the abrasive particles, wherein the filler is distinct from theabrasive particles based on at least one filler criteria selected fromthe group consisting of average particle size, composition, content,concentration, distribution, and a combination thereof.

Item 100. The abrasive article of item 99, wherein the abrasiveparticles comprises an average particle size (P1) and the fillercomprises a filler average particle size (F1), and wherein the averageparticle size is greater than the filler average particle size, whereinthe average particle size is at least about 5% different than the filleraverage particle size based on the equation ((P1−F1)/P1)×100%, at leastabout 10% different, at least about 20% different, at least about 30%different, and not greater than about 99% different.

Item 101. The abrasive article of item 99, wherein the filler comprisesan average particle size of not greater than about 500 microns, notgreater than about 300 microns, not greater than about 200 microns, notgreater than about 150 microns, not greater than about 100 microns, notgreater than about 80 microns, not greater than about 50 microns, notgreater than about 30 microns, not greater than about 20 microns, notgreater than about 15 microns, not greater than about 12 microns, notgreater than about 10 microns, not greater than about 8 microns, andwherein the filler comprises an average particle size of at least about0.01 microns.

Item 102. The abrasive article of item 99, wherein the filler comprisesa material selected from the group consisting of an inorganic material,an organic material, a polymer, a synthetic material, a naturalmaterial, and a combination thereof, wherein the filler comprises amaterial selected from the group consisting of a thermoplastic, athermoset, a resin, a ceramic, a glass, a metal, a metal alloy, a metalcoated particle, a substantially spherical bead, a hollow body, anelongated body, a fiber, and a combination thereof, wherein the fillercomprises a material selected from the group consisting of an oxide, acarbide, a nitride, a boride, diamond, a carbon-based material, cubicboron nitride, and a combination thereof, wherein the filler comprises aVickers hardness of at least about 0.1 GPa, at least about 1 GPa, suchas at least about 3 GPa, wherein the filler comprises a Vickers hardnessnot greater than about 200 GPa, not greater than about 150 GPa, notgreater than about 100 GPa.

Item 103. The abrasive article of item 99, wherein the abrasiveparticles comprise an average hardness (Hap) and the filler comprises afiller average hardness (Hf), and wherein the average hardness (Hap) isgreater than the filler average hardness (Hf), wherein the averagehardness is at least about 5% different than the filler average hardnessbased on the equation ((Hap−Hf)/Hap)×100%, at least about 10% different,at least about 20% different, at least about 30% different, and notgreater than about 99% different.

Item 104. The abrasive article of item 99, wherein the filler comprisesa filler composition distinct from an abrasive particle composition,wherein the filler composition is different from the abrasive particlecomposition by at least 5 wt. % of at least one element within thefiller composition and the abrasive particle composition.

Item 105. The abrasive article of item 99, wherein the abrasiveparticles are present in an abrasive particle content and the filler ispresent in a filler content, wherein the abrasive article includes anabrasive particle content greater than a filler content, wherein thefiller content is greater than the abrasive particle content, whereinthe abrasive particle content is substantially the same as the fillercontent, further comprising a particle count ratio (Cap:Cf) of abrasiveparticle content (Cap) to filler content (Cf) of not greater than about100:1, not greater than about 50:1, not greater than about 20:1, notgreater than about 10:1, not greater than about 5:1, not greater thanabout 2:1, and approximately 1:1, and wherein the particle count ratio(Cap:Cf) is at least about 2:1, at least about 5:1, at least about 10:1,at least about 20:1, at least about 50:1, at least about 100:1.

Item 106. The abrasive article of item 99, wherein the filler has agreater wetting affinity for a composition of the first layer ascompared to a wetting affinity of the abrasive particles relative to thecomposition of the first layer.

Item 107. The method of item 73, wherein processing according to thecontrolled processing condition includes heating the substrate, thefirst layer, and the abrasive particles to a re-flow temperature,wherein heating comprises selecting a re-flow temperature and aviscosity of the first layer and controlling the wetting of the firstlayer on the abrasive particles, wherein heating comprises selecting are-flow temperature corresponding to a predetermined viscosity of thefirst layer at the re-flow temperature to control the wetting of thefirst layer on the abrasive particles and controlling the averagemaximum thickness of the fillets.

Item 108. The method of item 107, wherein the re-flow temperature isless than a melting temperature of the first layer, wherein the re-flowtemperature is different than the melting temperature by at least about0.5% based on the equation [(Tm−Tr)/Tm]×100%, wherein Tm represents themelting temperature and Tr represents the re-flow temperature, whereinthe re-flow temperature is different than the melting temperature by atleast about 1%, at least about 2%, at least about 3%, at least about 4%,at least about 5%, at least about 8%, at least about 10%, at least about12%, at least about 15%, at least about 20%, at least about 30%, atleast about 40%.

Item 109. The method of item 107, wherein the re-flow temperature is notgreater than about 450° C., not greater than about 440° C., not greaterthan about 430° C., not greater than about 420° C., not greater thanabout 410° C., not greater than about 400° C., not greater than about390° C., not greater than about 380° C., not greater than about 370° C.,not greater than about 360° C., not greater than about 350° C., notgreater than about 340° C., not greater than about 330° C., not greaterthan about 320° C., not greater than about 310° C., not greater thanabout 300° C., and wherein the re-flow temperature is at least about100° C., at least about 120° C., at least about 150° C., at least about180° C., at least about 200° C., at least about 220° C.

Item 110. The method of item 73, wherein processing according to thecontrolled processing condition includes changing a viscosity of thefirst layer and controlling the wetting of the abrasive particles by thefirst layer, wherein processing according to the controlled processingcondition includes increasing a viscosity of the first layer andcontrolling the amount of wetting of the abrasive particles by the firstlayer.

Item 111. The method of item 73, wherein processing according to thecontrolled processing condition includes providing a filler to controlthe wetting of the first layer on the abrasive particles, whereinprocessing according to the controlled processing condition comprisesselecting at least one of a filler composition, a filler size, and afiller content to control the wetting of the first layer on the abrasiveparticles, wherein processing according to the controlled processingcondition includes providing a filler to control the average maximumthickness of the fillets.

Item 112. The method of item 73, wherein processing according to thecontrolled processing condition includes providing an atmosphericcondition selected from the group consisting of a reducing atmosphere,an oxidizing atmosphere, an inert atmosphere, an atmosphere consistingessentially of one element, and a combination thereof.

Item 113. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the substrate comprises a material selectedfrom the group consisting of metal, metal alloys, ceramic, glass, and acombination thereof, wherein the substrate comprises a metal comprisinga transition metal element, wherein the substrate comprises steel,wherein the substrate has an elongated body, the substrate comprises anelongated body having an aspect ratio of length:width of at least about10:1, wherein the substrate comprises an elongated body having an aspectratio of length:width of at least about 10000:1.

Item 114. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the substrate comprises an average length ofat least about 50 m, at least about 100 m, at least about 500 m, atleast about 1000 m, wherein the substrate comprises an average width ofnot greater than about 1 mm, not greater than about 0.8 mm, not greaterthan about 0.5 mm, wherein the core of the substrate comprises anaverage width of at least about 0.01 mm, wherein the substrate consistsessentially of a wire, wherein the core of the substrate comprises aplurality of filaments braided together.

Item 115. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, further comprising a barrier layer in direct contactwith a peripheral surface of the substrate, wherein the barrier layer isdisposed between the peripheral surface of the substrate and the firstlayer, wherein the barrier layer comprises an inorganic material,wherein the barrier layer comprises a metal or metal alloy, wherein thebarrier layer comprises a transition metal element, wherein the barrierlayer comprises a material different from the first layer, where in thebarrier layer consists of copper, wherein the barrier layer consistsessentially of nickel, wherein the barrier layer comprises a non-alloyedmaterial.

Item 116. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the first layer is configured to be a tackinglayer and provisionally hold the abrasive particles in place duringprocessing, wherein the first layer is in direct contact with a surfaceof the substrate.

Item 117. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the first layer comprises a material selectedfrom the group of materials consisting of metal, metal alloys, metalmatrix composites, and a combination thereof, wherein the first layercomprises a transition metal element, wherein the first layer comprisesan alloy of transition metal elements, wherein the first layer comprisestin, wherein the first layer comprises a metal selected from the groupof metals consisting of lead, silver, copper, zinc, tin, indium,titanium, molybdenum, chromium, iron, manganese, cobalt, niobium,tantalum, tungsten, palladium, platinum, gold, ruthenium, and acombination thereof, wherein the first layer comprises a metal alloy oftin and lead, wherein the first layer comprises tin, wherein the firstlayer consists essentially of tin.

Item 118. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the first layer comprises a solder material,wherein the first layer has a melting point of not greater than about450° C., not greater than about 400° C., not greater than about 375° C.,not greater than about 350° C., and at least about 100° C.

Item 119. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the first layer comprises an averagethickness of not greater than about 80% of an average particle size ofthe abrasive particles, not greater than about 70%, not greater thanabout 40%, and wherein the first layer comprises an average thickness ofat least about 7%, at least about 8%, at least about 9%, at least about10%, at least about 11%, at least about 12%, at least about 13%.

Item 120. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the abrasive particles comprises a materialselected from the group of materials consisting of oxides, carbides,nitrides, borides, oxynitrides, oxyborides, diamond, and a combinationthereof, wherein the abrasive particles comprises a superabrasivematerial, wherein the abrasive particles comprises diamond, the abrasiveparticles consists essentially of diamond, wherein the abrasiveparticles comprises a material having a Vickers hardness of at leastabout 10 GPa.

Item 121. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein the abrasive particles include a first typeof abrasive particle and a second type of abrasive particle differentthan the first type of abrasive particle, wherein the first type ofabrasive particle is different than the second type of abrasive particlebased on at least one particle characteristics selected from the groupconsisting of hardness, friability, toughness, particle shape,crystalline structure, average particle size, composition, particlecoating, grit size distribution, and a combination thereof.

Item 122. The abrasive article and method of item 121, wherein the firsttype of abrasive particle comprises a first average particle size (P1)and the second type of abrasive particle comprises a second averageparticle size (P2), and wherein the first average particle size isgreater than the second average particle size, wherein the first averageparticle size is at least about 5% different than the second averageparticle size based on the equation ((P1−P2)/P1)×100%, at least about10% different, at least about 20% different, at least about 30%different, and not greater than about 99% different.

Item 123. The abrasive article of any one of items 70, 71 and 72,wherein the bonding layer directly contacts at least a portion of thefirst layer, wherein the bonding layer directly contacts a portion ofthe abrasive particles, wherein the bonding layer directly contacts aparticle film layer on the abrasive particles, wherein the bonding layeroverlies a majority of an external surface of the substrate and anexternal surface of the abrasive particles.

Item 124. The abrasive article and method of any one of items 68, 69 and73, further comprising a bonding layer overlying the abrasive particles,wherein the bonding layer directly contacts at least a portion of thefirst layer, wherein the bonding layer directly contacts a portion ofthe abrasive particles, wherein the bonding layer directly contacts aparticle film layer on the abrasive particles, wherein the bonding layeroverlies a majority of an external surface of the substrate and anexternal surface of the abrasive particles.

Item 125. The abrasive article and method of item 124, wherein thebonding layer comprises a material selected from the group of materialsconsisting of metals, metal alloys, cements, ceramics, composites, and acombination thereof, wherein the bonding layer comprises a transitionmetal element, wherein the bonding layer comprises an alloy oftransition metal elements, wherein the bonding layer comprises a metalselected from the group of metals consisting of lead, silver, copper,zinc, tin, titanium, molybdenum, chromium, iron, manganese, cobalt,niobium, tantalum, tungsten, palladium, platinum, gold, ruthenium, and acombination thereof, wherein the bonding layer comprises nickel, whereinthe bonding layer consists essentially of nickel.

Item 126. The abrasive article and method of item 124, wherein thebonding layer comprises an average thickness of at least about 5% of anaverage particle size of the abrasive particles, wherein the bondinglayer comprises an average thickness of not greater than about 100% ofan average particle size of the abrasive particles.

Item 127. The abrasive article and method of item 124, wherein thebonding layer comprise an average thickness of at least about 1 micron,at least about 2 microns, at least about 3 microns, not greater thanabout 60 microns, not greater than about 50 microns, not greater thanabout 40 microns, not greater than about 30 microns.

Item 128. The abrasive article of any one of items 70, 71 and 72,wherein the bonding layer comprises a material selected from the groupof materials consisting of metals, metal alloys, cements, ceramics,composites, and a combination thereof, wherein the bonding layercomprises a transition metal element, wherein the bonding layercomprises an alloy of transition metal elements, wherein the bondinglayer comprises a metal selected from the group of metals consisting oflead, silver, copper, zinc, tin, titanium, molybdenum, chromium, iron,manganese, cobalt, niobium, tantalum, tungsten, palladium, platinum,gold, ruthenium, and a combination thereof, wherein the bonding layercomprises nickel, wherein the bonding layer consists essentially ofnickel.

Item 129. The abrasive article of any one of items 70, 71 and 72,wherein the bonding layer comprises an average thickness of at leastabout 5% of an average particle size of the abrasive particles, whereinthe bonding layer comprises an average thickness of not greater thanabout 100% of an average particle size of the abrasive particles.

Item 130. The abrasive article of any one of items 70, 71 and 72,wherein the bonding layer comprise an average thickness of at leastabout 1 micron, at least about 2 microns, at least about 3 microns, notgreater than about 60 microns, not greater than about 50 microns, notgreater than about 40 microns, not greater than about 30 microns.

Item 131. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, further comprising a coating layer overlying thesubstrate, wherein the coating layer overlies the bonding layer, whereinthe coating layer comprises a material selected from the group ofmaterials consisting of metals, metal alloys, cements, ceramics,organics and a combination thereof.

Item 132. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein further comprising an abrasive particleconcentration of the abrasive particles particle of at least about 5particles per mm of substrate, at least about 7 particles per mm ofsubstrate, at least about 10 particles per mm of substrate, at leastabout 20 particles per mm of substrate, at least about 30 particles permm of substrate, and not greater than about 800 particles per mm ofsubstrate.

Item 133. The method of item 73, wherein providing a body comprises:providing a substrate; forming the first layer using a depositionprocess selected from the group consisting of spraying, gravity coating,dipping, die coating, electrostatic coating, and a combination thereof;placing the abrasive particles on the first layer in contact with thefirst layer to bind the first type of abrasive particle to the firstlayer, wherein placing the first type of abrasive particle on the firstlayer comprises a deposition process selected from the group consistingof spraying, gravity coating, dipping, die coating, electrostaticcoating, and a combination thereof; wherein placing the abrasiveparticles on the first layer includes placing an additional layercomprising a flux material overlying the first layer; and furthercomprising heating the first layer to a temperature of not greater thanabout 450° C.

Item 134. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein at least a portion of the abrasive particlesare spaced apart from an upper surface of the substrate, wherein amajority of the abrasive particles are spaced apart from an uppersurface of the substrate.

Item 135. The abrasive article and method of any one of items 68, 69,70, 71, 72 and 73, wherein at least about 55% of the abrasive particleshave an undercut region, at least about 60%, at least about 70%, atleast about 80%, at least about 90%, at least about 95%.

What is claimed is:
 1. An abrasive article comprising: a substratecomprising an elongated member; a first layer overlying the substrate;abrasive particles overlying the first layer; fillets connecting thefirst layer and the abrasive particles; and a bonding layer overlyingthe abrasive particles, wherein the fillets have a tacking factor(t_(fl)/t_(f)) of at least about 0.1 and not greater than about 2.0,wherein t_(fl) represents an average thickness of the first layer andt_(f) represents an average thickness of the fillets.
 2. The abrasivearticle of claim 1, wherein the tacking factor (t_(fl)/t_(f)) is atleast about 0.5 and not greater than about 1.5, wherein t_(fl)represents an average thickness of the first layer and t_(f) representsan average maximum thickness of the fillets.
 3. An abrasive articlecomprising: a substrate comprising an elongated member; a first layeroverlying the substrate; abrasive particles overlying the first layer;and fillets connecting the first layer and the abrasive particles,wherein the fillets have a tacking factor (t_(fl)/t_(f)) of at leastabout 0.1 and not greater than about 2.0, wherein t_(fl) represents anaverage thickness of the first layer and t_(f) represents an averagethickness of the fillets.
 4. The abrasive article of claim 3, whereinthe tacking factor (t_(fl)/t_(f)) is at least about 0.5.
 5. The abrasivearticle of claim 3, further comprising a fillet-to-particle factor(t_(f)/d_(ab)) of at least about 0.05 and not greater than about 0.32,wherein t_(f) represents an average maximum thickness of the fillets andd_(ab) represents and an average particle size of the abrasiveparticles.
 6. The abrasive article of claim 3, further comprising afillet-to-bonding layer factor (t_(f)/t_(bl)) of not greater than about100 and at least about 10, wherein t_(f) represents an average maximumthickness of the fillets and t_(bl) represents and an average thicknessof the bonding layer.
 7. The abrasive article of claim 3, furthercomprising a contact factor (A_(b)/A_(f)) of at least about 1.0 and notgreater than about 10, wherein A_(b) represents an average percentage ofa surface area of the abrasive particles in contact with the bondinglayer, and A_(f) represents an average percentage of the surface area ofthe abrasive particles in contact with the fillets.
 8. The abrasivearticle of claim 3, further comprising a fillet size variance (V_(f)) ofnot greater than about 60% and at least about 2%.
 9. The abrasivearticle of claim 3, wherein the fillets comprise a metal.
 10. Theabrasive article of claim 3, wherein the fillets comprise a mixture of acomposition of the first layer and an active bonding material.
 11. Theabrasive article of claim 10, wherein the fillets comprise at least twodiscrete phases of material including a first phase and a second phase.12. The abrasive article of claim 10, wherein the first phase ispreferentially located closer to a surface of the abrasive particles ascompared to the second phase.
 13. The abrasive article of claim 3,wherein the fillets comprises at least three discrete phases of materialincluding a first phase, a second phase, and a third phase.
 14. Theabrasive article of claim 3, further comprising a filler in the firstlayer distinct from the abrasive particles, wherein the filler isdistinct from the abrasive particles based on at least one fillercriteria selected from the group consisting of average particle size,composition, content, concentration, distribution, and a combinationthereof.
 15. A method of forming an abrasive article comprising:providing a body including abrasive particles overlying a first layer,the first layer overlying a substrate; processing at least thesubstrate, the first layer, and the abrasive particles according to acontrolled processing condition to form an abrasive article having atacking factor (t_(fl)/t_(f)) of at least about 0.1 and not greater thanabout 2.0, wherein t_(fl) represents an average thickness of the firstlayer and t_(f) represents an average thickness of the fillets; andwherein the controlled processing condition is selected from the groupconsisting of re-flow temperature, filler content, filler size, fillercomposition, average particle size of the abrasive particles, sizedistribution of the abrasive particles, content of the abrasiveparticles, composition of the abrasive particles, thickness of the firstlayer, composition of the first layer, and a combination thereof. 16.The method of claim 15, wherein processing according to the controlledprocessing condition includes heating the substrate, the first layer,and the abrasive particles to a re-flow temperature.
 17. The method ofclaim 16, wherein the re-flow temperature is different than a meltingtemperature by at least about 0.5% based on the equation[(Tm−Tr)/Tm]×100%, wherein Tm represents the melting temperature of thefirst layer and Tr represents the re-flow temperature.
 18. The method ofclaim 16, wherein the re-flow temperature is not greater than about 450°C. and at least about 100° C.
 19. The method of claim 15, whereinprocessing according to the controlled processing condition includeschanging a viscosity of the first layer and controlling the wetting ofthe abrasive particles by the first layer.